Page 1
ts
OM-272 158A
2015−09
Endeavor Seriest
Auto-Darkening Welding Helme
www.HobartWelders.com
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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 5..........................................
3-1. Helmet Controls 5..............................................................
3-2. Reset Button And Low Battery Indicator 5..........................................
3-3. Lens Delay Control 6...........................................................
3-4. Variable Shade Control (No. 8 − 13) 6.............................................
3-5. Sensitivity/Grind Mode Control 7..................................................
SECTION 4 − ADJUSTING HEADGEAR 8..............................................
SECTION 5 − REPLACING THE LENS COVERS 9......................................
5-1. Replacing Outside Lens Cover 9.................................................
5-2. Replacing Inside Lens Cover 10..................................................
SECTION 6 − REPLACING THE BATTERIES 11........................................
SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS 11..........................
SECTION 8 − MAINTENANCE 12.....................................................
SECTION 9 − TROUBLESHOOTING 12................................................
SECTION 10 − PARTS LIST 13.......................................................
SECTION 11 − LIMITED WARRANTY 13...............................................
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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-272 158 Page 1
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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.
Wear 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-272 158 Page 2
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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: 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-272 158 Page 3
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SECTION 2 − SPECIFICATIONS
Notes
Cartridge Dimensions 4.53 x 5.2 x 0.39 in. (115 x 132 x 10 mm)
Viewing Field 3.82 x 2.36 in. (97 x 60 mm); 9.02 in2 (58.2 cm2)
Reaction Time 0.000067 Second (1/15,000 Second)
Available Shades Darkened State: No. 8 − No. 13 / Light State: No. 3
Sensors Independent/Redundant (Four)
Operating Temperature 23F to 131F / −5C to +55C
Provides Continuous UV And IR Protection
When stored in extremely cold temperatures, warm
helmet t o ambient temperature before welding.
Storage Temperature 14F to 158F / −10C to +70C
When stored in extremely cold temperatures, warm
helmet t o ambient temperature before welding.
Power Supply CR2450 Lithium Batteries (2)
Total Weight 19.4 oz (550 g)
Standards ANSI Z87.1-2010 and DIN/CE/TUV/CSA
Warranty Two Years From Date Of Purchase (See Section 11)
Sensitivity/Grind Mode Control 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 Illuminates To Indicate 2−3 Days Remaining
1.0 Seconds
Battery Life
OM-272 158 Page 4
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Page 7
SECTION 3 − OPERATING INSTRUCTIONS
3-1. Helmet Controls
12 3 45
3-2. Reset Button And Low Battery Indicator
1 Sensitivity/Grind Mode Control
(See Section 3-5)
2 Low Battery Indicator
(See Section 3-2)
3 Reset Button (See Section 3-2)
4 Lens Delay Control
(See Section 3-3)
5 Variable Shade Control (See
Section 3-4)
The auto-darkening lens
turns on (darkens) automatically when welding begins
and turns off 15−20 minutes
after welding stops.
1 Reset Button
Press Reset button to check if the
lens is worki n g p r o p e r l y.
When the Reset button is
pressed, the lens should darken
twice and return to the clear state.
Do not use the helmet if the lens
does not function as described.
(See Section 9, Troubleshooting.)
2 Low Battery Indicator
The low battery indicator lights
when 2−3 days of battery life remain.
If battery power is low, install ne w
CR2450 lithium batteries (see
2
1
Section 6).
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3-3. Lens Delay Control
1
3-4. Variable Shade Control (No. 8 − 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).
OM-272 158 Page 6
1 Variable Shade Control
(No. 8 − 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 and adjust lighter
to suit the welding application and
your personal preference.
1
Page 9
3-5. Sensitivity/Grind Mode Control
1
1 Sensitivity/Grind Mode Control
Weld Mode
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 ap-
plications.
It may be necessary to adjust helmet sensitivity to accommodate different lighting conditions or i f lens is flashing On and Off. Adjust helmet sensitivity as follows:
Adjust helmet sensitivity in lighting con-
ditions helmet will be used in.
Turn sensitivity control to lowest
setting.
Press Reset button to turn helmet On.
Helmet lens will darken twice and then
clear.
Face the helmet in the direction of use,
exposing i t t o the surrounding light conditions.
Gradually turn sensitivity setting clock-
wise 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
on and off.
Grind Mode
Do not weld in the Grind mode; the lens
will not darken.
To use the Grind mode, turn the Sensitivity
control clockwise to the far right position
(Grind). To resume welding, return the control to the desired sensitivity setting.
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
Grind Mode Grind Position − Far Right (Clockwise)
OM-272 158 Page 7
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SECTION 4 − ADJUSTING HEADGEAR
There are four headgear adjust-
1 Headgear Top
Adjusts headgear for proper depth
on the head to ensure correct bal-
1
ance and stability.
2 Headgear Tightness
3
To adjust, press knob and turn left or
right to desired 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
slots. Move headgear 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
2
4
adjust, loosen the right outside tension adjustment knob then lift the
control arm tab and move it to the desired position. Retighten tension adjustment knob.
ments: headgear top, tightness,
angle adjustment, and distance
adjustment.
necessary to remove the comfort cushion.
OM-272 158 Page 8
When using the back distance
adjustment positions, only the
back three angle adjustment
pins can be used.
Page 11
SECTION 5 − REPLACING THE LENS COVERS
5-1. Replacing Outside Lens Cover
2
2
1
! 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.
1 Front Lens Holder
2 Release Points
3 Lens Cover
4 Gasket
Remove front lens holder by press-
ing release points and pulling the
holder away from the helmet.
Remove lens cover and gasket from
the holder. Replace lens cover and
reinstall gasket and lens in holder.
Reinstall holder in helmet.
Be sure the flat side of lens cov-
er gasket faces the lens cover
holder.
Be sure flat side of gasket
faces lens cover holder.
4
3
OM-272 158 Page 9
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5-2. Replacing Inside Lens Cover
-
-
)
t
f
r
-
! 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.
Remove front lens holder (see Section
5-1). Remove auto-darkening lens assem
bly by pressing it gently from inside the hel
met. (Assembly comes out front of helmet.
1 Lens Assembly
2 Inside Lens Cover
Remove the inside lens cover by prying the
cover up at either thumbnail opening a
each side of the cover. Slide cover it out o
either side of frame. Replace lens cove
and reinstall the assembly in the helmet by
reversing the above procedure.
Be sure the cover lens is seated prop
erly (flat) to prevent fogging.
1
OM-272 158 Page 10
2
Page 13
SECTION 6 − REPLACING THE BATTERIES
To replace the batteries, remove
the auto-darkening lens
assembly (see Section 5-2).
1
++
Be sure Positive
(+) side of battery
faces up.
1 Battery Tray
After removing the lens assembly,
slide the battery holding trays out
and remove the old batteries.
Replace with CR2450 lithium type
batteries ( 2 required) or equivalent
(Miller Part No. 217043).
Be sure Positive (+) side of the
battery faces up (toward inside
of helmet).
Reinstall the battery trays. To test,
press the Reset button. The lens
should flash dark twice. Reinstall
the lens assembly.
Left and right battery trays are
not interchangeable. The
auto−darkening helmet will not
work if battery trays are
installed on the wrong sides.
OTOS / 804 847
SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS
1 Optional Magnifying Lens
Starting a t the top, slide magnifying
lens into the helmet retaining brackets. Align the magnifying lens with
the auto-darkening lens assembly.
Reverse procedure to remove
magnifying lens.
1
T o prevent lens fogging, install
flat side of magnifying lens toward auto-darkening lens.
OM-272 158 Page 11
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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 will not darken momentarily when the Reset
button is pressed.
Not switching – auto-lens
stays light and will not
darken when welding.
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. Verify left and right battery trays are
installed on the correct sides.
Stop welding immediately.
Press the Reset button if lens is Auto-On type. If lens is Manual-
On type, 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-272 158 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.
Page 15
SECTION 10 − PARTS LIST
2
1
4
3
5
Figure 10-1. Endeavor Series Auto-Darkening Welding Helmets
Item
No. Quantity
Part
No.
Description
Figure 10-1. Endeavor Series Auto-Darkening Welding Helmets
1 770831 Kit, Replacement Frame And Gasket 1.............. ...... ................
2 770586 Kit, Replacement Clear Lens.............. ......
3 770823 Lens, Auto-Darkening (ADF Cartridge Assembly) 1.............. ...... .....
4 770613 Headgear, Ratcheting Adjustable 1.............. ...... ...................
5 ♦770274 Diopter Lens, 150X (1.50 Magnification) 1............ ...... .............
♦770276 Diopter Lens, 200X (2.00 Magnification) 1............... ...... .............
♦770277 Diopter Lens, 250X (2.50 Magnification) 1............... ...... .............
(Includes 5 Outside / 2 Inside) 1.............................. ......................
Battery, Non−rechargeable CR2450 2.............................. .................
♦ Optional
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 2015-01
Effective January 1, 2015
OM-272 158 Page 13
Page 16
Hobart Brothers Co.
2200 Corporate Drive
Troy, OH 45373 USA
Phone: 800-332-3281
Visit our website at
www.HobartWelders.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2015 Hobart Welders 2015-01
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