Hobart HELMET: DISCOVERY VS SERIES AUTO-DARKENING User guide

s

OM-257 076C
2014−02

Discovery VS Series

Auto-Darkening Welding Helmet

www.HobartWelders.com

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 3....................................................

1-4. Lens Shade Selection Table 3.................................................

1-5. Principal Safety Standards 3..................................................

SECTION 2 − SPECIFICATIONS 4.....................................................

SECTION 3 − OPERATING INSTRUCTIONS 4..........................................

3-1. Helmet Controls 4...........................................................

3-2. Low Battery Indicator 5.......................................................

3-3. Weld On/Grind On Switch 5...................................................

3-4. Lens Delay Control 6.........................................................

3-5. Variable Shade Control (No. 9 − 13) 6...........................................

3-6. Sensitivity Control 7..........................................................

SECTION 4 − ADJUSTING HEADGEAR 8..............................................

SECTION 5 − REPLACING THE LENS COVERS 9......................................

5-1. Replacing Outside Protective Lens 9............................................

5-2. Replacing Inside Protective Lens 10............................................

5-3. Removing Auto-Darkening Lens Assembly 11....................................

SECTION 6 − REPLACING THE BATTERY 12..........................................

SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS 12..........................

SECTION 8 − MAINTENANCE 13.....................................................

SECTION 9 − TROUBLESHOOTING 13................................................

SECTION 10 − PARTS LIST 15.......................................................

SECTION 11 − LIMITED WARRANTY 16...............................................

SECTION 1 − WELDING HELMET SAFETY PRECAUTIONS −

READ BEFORE USING

helmet 2013-09

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 body protection made from durable, flame−resistant material (leather, heavy cotton,

wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.

• 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.

OM-257 076 Page 1

WELDING HELMETS do not provide unlimited eye, ear, an

d

t

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.

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 in-

stalling, 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. The recommended way to determine adequate ventilation is to sample f or
the composition and quantity of fumes and gases to which personnel are exposed.

 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for

adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

 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 i s 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.

OM-257 076 Page 2

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.

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-257 076 Page 3

SECTION 2 − SPECIFICATIONS

Discovery VS (No. 9 − No. 13 Variable Shade)

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)
Available Shades Darkened State: No. 9 − 13 / Light State: No. 4
Grind Mode Yes
Sensors Independent/Redundant (2)
Operating Temperature 23F to 131F (−5C to +55C)
Storage Temperature 14F to 158F (−10C to +70C)
Power Supply One CR2450 Lithium Battery
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 Last Arc Is Struck
Low Battery Indicator Red LED Light Illuminates To Indicate Low Battery
Total Weight 18 oz (510.3 g)
Standards ANSI Z87.1-2010 CE/CSA
Warranty Two Years From Date Of Purchase (See Section 11)

1.0 Second (Infinite Dial Control)

SECTION 3 − OPERATING INSTRUCTIONS

3-1. Helmet Controls

1 23456

OM−257 076 Page 4

 The auto-darkening lens turns on

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

1 Variable Shade Control (See

Section 3-5)

2 Weld On/Grind On Switch (See

Section 3-3)

3 Low Battery Indicator

(See Section 3-2)

4 Sensitivity Control

(See Section 3-6)

5 Delay Control

(See Section 3-4)

6 Battery Compartment (See

Section 6)

3-2. Low Battery Indicator

1

3-3. Weld On/Grind On Switch

 The auto-darkening lens turns on

(darkens) automatically when weld­ing begins 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

CR2450 lithium battery.

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

1

applications, move the switch to the Grind
On (down) position.

OM−257 076 Page 5

3-4. Lens Delay Control

1

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

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
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).

1

OM−257 076 Page 6

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.

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

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.

OM−257 076 Page 7

SECTION 4 − ADJUSTING HEADGEAR

1

23

4

 There are four headgear adjust-

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

1 Headgear Top
Adjusts headgear for proper depth

on the head to ensure correct bal­ance and stability.

2 Headgear Tightness
To adjust, push in the adjusting knob

located o n the back of the headgear
and turn left or right to desired tight­ness.

 If adjustment is limited, it may be

necessary to remove the com­fort cushion.

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

4 Angle Adjustment
Four 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.

OM−257 076 Page 8

 When using the back distance

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

SECTION 5 − REPLACING THE LENS COVERS

-

-

-

y

r

s

5-1. Replacing Outside Protective Lens

! Never use the auto-

darkening lens with­out the inside and
outside lens covers
properly installed.
Welding spatter will
damage the auto­darkening lens and
void the warranty.

1 Auto-Darkening Lens

Retainer Clips

2 Auto-Darkening Lens

Retainer

3 Auto-Darkening Lens

Assembly

4 Outside Protective

Lens (Clear)
5 Gasket
Place helmet upside down

345

on a flat surface.
Adjust or remove headgear

to improve access to lens
assembly.

Gently release the top and
bottom auto−darkening
lens retainers located in­side the helmet. Lift out
auto−darkening lens as­sembly. Hold assembly
and press outside lens and
gasket from front.
(Assembly comes out
through t h e back of the hel­met.)

Replace clear lens with
new lens (Reuse the rubber
gasket.)

2

 Use the rubber gasket

to keep weld spatter

1

away from the auto−
darkening lens.

Reinstall new outside pro
tective lens with gasket and
reinstall auto darkening
lens in the plastic lens re
tainer.

Reinstall the retainer and
secure the top and bottom
lens retainer clips.

 The outside lens gas

ket must be correctl
installed for maximum
lens protection.

 Call 800−626−9420 fo

assistance in replacing
lens assembly or len
covers.

OM−257 076 Page 9

5-2. Replacing Inside Protective Lens

t

r

r

s

2

34

1

! Never use the auto-

darkening lens with­out the inside and
outside lens covers
properly installed.
Welding spatter will
damage the auto­darkening lens and
void the warranty.

1 Auto-Darkening Lens

Retainer Clips

2 Auto-Darkening Lens

Assembly

3 Auto-Darkening Lens

Retainer

OM−257 076 Page 10

4 Inside Protective Lens

(Clear)

Place helmet upside down
on a flat surface.

Adjust or remove headgear
to improve access to lens
assembly.

Gently release the top and
bottom auto−darkening
lens retainers located in­side the helmet. Lift out
auto−darkening lens as­sembly.

Gently remove auto dark­ening lens assembly from

retainer by releasing the
four tabs.

Remove inside protective
lens at the marked locations
and replace with new lens.

 Use the rubber gaske

to keep weld spatte
away from the auto−
darkening lens.

 Call 800−626−9420 fo

assistance in replacing
lens assembly or len
covers.

5-3. Removing Auto-Darkening Lens Assembly

­.

-

-

­f

r

g

s

! Never use the auto-

darkening lens with­out the inside and
outside lens covers
properly installed.
Welding spatter will
damage the auto­darkening lens and
void the warranty.

1 Auto-Darkening Lens

Retainer Clips

2 Auto-Darkening Lens

Assembly

3 Auto-Darkening Lens

Retainer

4 Shade Control Knob

2

Place helmet upside down
on a flat surface.

Adjust or remove headgear
to improve access to lens
assembly.

Gently release the top and
bottom auto−darkening
lens retainers located in­side the helmet. Lift out
auto−darkening lens as­sembly.

Gently remove auto dark­ening lens assembly from
retainer by releasing the
four tabs.

3

1

Remove the outside Shade
Control knob by prying un
derneath with a thin object
(The knob retainer has two
clips.)

Remove Shade Control re
tainer nut and 9 − 13 indicat
or ring. Remove switch as
sembly from the inside o
the helmet.

Reinstall lens assembly in
reverse order of removal.

 Call 800−626−9420 fo

assistance in replacin
lens assembly or len
covers.

OM−257 076 Page 11

4

SECTION 6 − REPLACING THE BATTERY

1 Battery Cover
Remove battery by turning battery

cover counterclockwise.

1

Replace with CR2450 lithium bat­tery.

 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

OM−257 076 Page 12

ward auto-darkening lens.

SECTION 8 − MAINTENANCE

NOTICE − Never use solvents or abrasive cleaning detergents.
NOTICE − 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.

SECTION 9 − TROUBLESHOOTING

Trouble Remedy

Auto-lens not On; auto­lens does not darken mo­mentarily when arc is
struck or On button is
pressed.

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

Auto-lens not switching –
auto-lens stays dark after
the 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.

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 on. 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.

Review sensitivity recommendations and adjust sensitivity if pos­sible. Do not weld in the Grind On mode; the lens will not darken.

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 or cutting 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).

OM−257 076 Page 13

Trouble Remedy

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

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

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.

Review the sensitivity setting recommendations and increase the
sensitivity if possible. Increasing Lens Delay 0.1 − 0.3 second
may also reduce switching.

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.

OM−257 076 Page 14

SECTION 10 − PARTS LIST

1

3

4

2

5

Figure 10-1. Auto-Darkening Welding Helmet

Item

No. Quantity

Part

No.

Description

Figure 10-1. Auto-Darkening Welding Helmet

1 770676 Kit, Helmet Hardware 1........ .... ....................................

2 770493 Kit, Clear Lens (Includes 5 Outside Lenses/2 Inside Lenses) 1........ .... ...

3 770762 Replacement Auto-Darkening Lens 1........ .... ........................

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

4 770613 Ratchet Headgear Assembly 1........ .... ..............................

5 ♦770274 Diopter Lens 150X 1........ ... ......................................

♦770275 Diopter Lens 175X 1.......... ... ......................................

♦770276 Diopter Lens 200X 1.......... ... ......................................

♦770277 Diopter Lens 250X 1.......... ... ......................................

♦ Optional

OM−257 076 Page 15

SECTION 11 − LIMITED WARRANTY

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

Co., Troy, Ohio, warrants to its original retail purchaser that the new Hobart 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.

Hobart auto-darkening lens helmets are warranted for two (2) years 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 Hobart retailer or call

1−800−332−3281

Hob Helm 2014-01

Effective January 1, 2014

OM−257 076 Page 16

Hobart Brothers Co.
2200 Corporate Drive
Troy, OH 45373 USA
Phone: [phone]

Visit our website at

www.HobartWelders.com

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2014 Hobart Welders 2014-01