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OM-221 534E
2011−11
Auto-Darkening Welding Helmets
HOBART XFS Series
)
)
HOBART XVS Series
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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 2....................................................
SECTION 2 − SPECIFICATIONS 3.....................................................
SECTION 3 − OPERATING INSTRUCTIONS 4..........................................
3-1. Helmet Controls − XFS Model 4................................................
3-2. Helmet Controls − XVS Model 4................................................
3-3. On Button And Low Battery Indicator − XVS Model 5..............................
3-4. Lens Delay Control − XVS Model 5.............................................
3-5. Variable Shade Control − XVS Model 6..........................................
3-6. Sensitivity Control − XVS Model 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 9.................................................
SECTION 6 − REPLACING THE BATTERY 10..........................................
SECTION 7 − MAINTENANCE 10.....................................................
SECTION 8 − TROUBLESHOOTING 11................................................
SECTION 9 − LIMITED WARRANTY 12................................................
SECTION 10 − PARTS LIST 13.......................................................
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SECTION 1 − WELDING HELMET SAFETY PRECAUTIONS −
READ BEFORE USING
helmet 2011−10
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 or 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! Watch
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 Shade
and Sensitivity charts.
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 and
face protection.
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.
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.
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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 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 to 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.
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download 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).
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SECTION 2 − SPECIFICATIONS
XFS Technical Specifications (Fixed Shade No.10)
Cartridge Dimensions 4.33 x 3.54 x 0.39 in. (110 x 90 x 10 mm)
Viewing Field 3.75 x 1.37 in. (95 x 35 mm)
Reaction Time Light To Dark: 0.00028 second (1/3,600)
Available Shades Darkened State: No. 10 / Light State: No. 3
Sensors Independent (2)
Operating Temperature 23F to 131F (−5C to +55C)
Storage Temperature −4F to 176F (−20C to +80C)
Power Supply Battery-Powered, Solar Rechargeable
Total Weight 0.9 lb (410g)
Standards ANSI Z87.1-2003/CSA
Warranty 2 Years From Date Of Purchase (See Section 9)
XVS Technical Specifications (No. 9 − No. 13 Variable Shade)
Dark To Light: 0.12 Second
(Internal, Non-Replaceable Lithium Battery)
Cartridge Dimensions 4.33 x 3.54 x 0.39 in. (110 x 90 x 10 mm)
Viewing Field 3.75 x 1.57 in. (95 x 40 mm)
Reaction Time 0.000083 Second (1/12,000)
Available Shades ANSI: Darkened State: No. 9 − 12 / Light State: No. 4
CE/CSA: Darkened State: No. 9 − 13 / Light State: No. 4
Sensors Independent/Redundant (2)
Operating Temperature 23F to 131F (−5C to +55C)
Storage Temperature 14F to 158F (−10C to +70C)
Power Supply Two AAA Alkaline Batteries (Included)
Total Weight 1.01 lb (460g)
Standards ANSI Z87.1-2003 CE/CSA
Warranty 2 Years From Date Of Purchase (See Section 9)
Sensitivity Control light levels Adjusts For Varying Ambient Light And Welding 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
0.5 Second (Fast/Slow Switch)
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SECTION 3 − OPERATING INSTRUCTIONS
3-1. Helmet Controls − XFS Model
2
1
Expose the solar cell to
bright sunlight for 30 minutes
before using welding helmet.
The XFS model uses a
non-replaceable Lithium
battery.
The XFS model has no On
button. The helmet turns on
automatically.
1 Auto-Darkening Lens
2 Solar Cell
3-2. Helmet Controls − XVS Model
4 5
3
2
1
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The XVS model uses two
AAA Alkaline batteries.
Press the On button to turn
6
on the XVS auto-darkening
lens. The lens turns off automatically (clear state − No. 4)
15−20 minutes after the last
arc.
1 Auto-Darkening Lens
2 Low Battery Indicator
(Section 3-3)
3 On Button (Section 3-3)
4 Battery Compartment
(Section 6)
5 Shade Control
(Section 3-5)
6 Sensitivity Control
7
(Section 3-6)
7 Lens Delay Control
(Section 3-4)
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3-3. On Button And Low Battery Indicator − XVS Model
1 On Button
Press the On button to check if the
lens is working properly.
When the On 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
Troubleshooting, Section 8).
1
2
3-4. Lens Delay Control − XVS Model
1
The lens turns off automatic-
ally (clear state − No. 4) 15−20
minutes after the last arc.
Press the On button to resume welding.
2 Low Battery Indicator
The low battery indicator lights
when 2−3 days of battery life remains.
If battery power is low, replace the
two AAA Alkaline batteries (see
Section 6).
1 Lens Delay Control
The lens delay control is used to
adjust 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
fast to slow.
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3-5. Variable Shade Control − XVS Model
1
1 Variable Shade Control
(No. 9 − 13)
Use the control to adjust the lens
shade in the darkened state. Use
the table below to select proper
shade control setting based on
your welding process.
Start at shade 13 and adjust lighter
to suit the welding application and
your personal preference.
Application Welding Arc Current in Amperes Protective Shade No.
Stick Electrodes Less than 40
MIG Less than 100
Gas Tungsten Arc Welding
(TIG)
Air Carbon Less than 500
Plasma Arc Cutting 60−150
Plasma Arc Welding Less than 50
OM-221 534 Page 6
40−80
80−175
175−300
300−500
100−175
175−300
300−500
Less than 50
50−100
100−200
200−400
500−700
150−250
250−400
50−200
200−400
9
10
11
12
13
10
11
12
13
10
11
12
13
12
13
11
12
13
9
10
12
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3-6. Sensitivity Control − XVS Model
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 helmet sensitivity as follows:
Adjust helmet sensitivity in light-
ing conditions helmet will be
used in.
Turn sensitivity control to lowest
setting.
Press On button to turn helmet
On. Helmet lens will darken
twice and then clear.
Face the helmet in the direction
of use, exposing it to the surrounding light conditions.
Gradually turn sensitivity 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 on and off.
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
OM−221 534 Page 7
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SECTION 4 − ADJUSTING HEADGEAR
The helmet view is typical of all
units. Your helmet may differ
slightly from that shown.
There are four headgear adjust-
ments: headgear top, tightness,
angle adjustment, and distance
adjustment.
1
3
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 on 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
2
4
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.
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When using the back distance
adjustment positions, only the
back three angle adjustment
pins can be used.
804 118
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SECTION 5 − REPLACING THE LENS COVERS
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-darkening 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 cover
lens by prying the lens up at the thumbnail
opening located at the top center of the cover 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 of
the auto-darkening lens assembly.
Be sure the cover lens is seated prop-
erly (flat) to prevent fogging.
1
804 793 / 804 794
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SECTION 6 − REPLACING THE BATTERY
The XFS helmet has a non-replaceable Lithium battery.
1 XVS Auto-Darkening Lens
2 Battery Cover
Slide cover to left and remove batter-
ies. Install two AAA Alkaline batteries
and replace cover.
Be sure the positive (+) side of the
battery is aligned with positive (+)
terminal.
2
LOCKOPEN
1
AAA BATTERY
SECTION 7 − 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.
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SECTION 8 − TROUBLESHOOTING
Trouble Remedy
Auto-lens not On; autolens does not darken momentarily when arc is
struck (XFS) or On button
is pressed (XVS).
Auto-lens not switching –
auto-lens stays light and
does not darken when
welding or cutting.
Not Switching – auto-lens
stays dark after the arc is
extinguished, or the autolens stays dark when no
arc is present.
Sections of the auto-lens
are not going dark, distinct
lines separate the light and
dark areas.
XFS Models:
Expose the solar cell to bright sunlight for 30 minutes before use.
XVS Models:
Check batteries and verify they are in good condition and installed
properly.
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.
All Models: Stop welding or cutting 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.
XVS Models:
Review sensitivity recommendations and adjust sensitivity if possible.
XVS Models:
Reduce Sensitivity setting (see Section 3-6). In extreme light conditions, it may be necessary to reduce the surrounding light levels.
If the lens remains dark, press the On button to return lens to the
clear state.
Stop welding or cutting immediately: The auto-lens may be
cracked which can be caused by the impact 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).
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. Increasing Lens Delay 0.1 − 0.3
second may also reduce switching.
XVS Models: Review the sensitivity setting recommendations
and increase the sensitivity if possible.
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.
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SECTION 9 − LIMITED WARRANTY
Not
LIMITED WARRANTY – Subject to the terms and conditions below. Hobart Welding
Retail, Appleton, Wisconsin, 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
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES OR MERCHANTABILITY AND
FITNESS.
Hobart XFS and XVS auto-darkening lens helmets are warranted for two (2) years
from the date of purchase. Proof of purchase is required for warranty transac-
tions 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
Effective January 1, 2010
OM-221 534 Page 12
es
Hobart Welding Products
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 800-332-3281 (Warranty Service)
or 800−626−9420 (Product Information)
Page 15
SECTION 10 − PARTS LIST
1
4
2
3
803 935
Figure 10-1. XFS And XVS Series Auto-Darkening Welding Helmets
Item
No. Quantity
Part
No.
Description
Figure 10-1. XFS And XVS Series Auto-Darkening Welding Helmets
1 *770 425 Kit, Lens Cover Flat Black 1........... ........ .........................
1 *770 426 Kit, Lens Cover Gloss Black 1........... ........ .......................
1 *770 647 Kit, Lens Cover Patriot II (Blue) 1........... ........ .....................
1 *770 454 Kit, Lens Cover Blaze Orange 1........... ........ ......................
1 *770 493 Kit, Clear Lens (Bezel Not Included) 1........... ........ ................
2 770 455 Lens, Helmet Auto Darkening (XFS Series) 1............ ........ ..........
2 770 427 Lens, Helmet Auto Darkening (XVS) Series) 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........... ....... ...............
(5 Outside Lenses, 5 Inside Lenses).............................. ................
* Includes bezel, front lens cover gasket, 5 front lens covers, 2 inside lens covers.
♦ Optional
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Visit our website at
www.hobartwelders.com
Hobart Welding Products
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 800-332-3281 (Warranty Service)
or 800−626−9420 (Product Information)
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ORIGINAL INSTRUCTIONS © 2010 Hobart Welding Products
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