COOL-SHIELD AUTO-DARKENING FILTER CARTRIDGE (ADF) HELMETS IM0000 February, 2009 This manual covers equipment which is no longer in production by The Lincoln Electric Co. Specifications and availability of optional features may have changed. OPERATOR S MANUAL Copyright Lincoln Global Inc. World's Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland, Ohio 447-99 U.S.A. TEL: 26.48.800 FAX: 26.486.75 WEB SITE: www.lincolnelectric.com
TABLE OF CONTENTS Page SAFETY WARNINGS READ BEFORE USING PATENT INFORMATION 2 SPECIFICATIONS 2 OPERATING INSTRUCTIONS 3 AUTO-DARKENING CARTRIDGE CONTROLS 4 SHADE GUIDE 5 LENS REPLACEMENT 6 AUTO-DARKENING CARTRIDGE ACCESS AND REPLACEMENT 7 HELMET CARE AND MAINTENANCE 8 TROUBLE SHOOTING 9-0 WARRANTY INFORMATION 0 REPLACEMENT PARTS
SAFETY WARNINGS READ BEFORE USING WARNING ARC Rays can injure eyes and burn skin Before welding, always inspect helmet and filter lens to be sure they are fitted properly, in good condition and not damaged. Check to see that the clear lens is clean and securely attached to the helmet. Always wear safety glasses or goggles under the welding helmet and protective clothing to protect your skin from radiation, burns and spatter. Ensure that optical radiation from other welder s arcs in the immediate area does not enter in from behind the helmet and auto-darkening filter. Note: Auto-darkening filters in Lincoln helmets are designed to protect the user against harmful ultra-violet and infrared rays both in the dark and light states. No matter what shade the filter is set to, the UV/IR protection is always present. FUMES AND GASES can be dangerous to your health. Keep your head out of fumes. Use enough ventilation or exhaust at the arc or both to keep fumes and gases from your breathing zone and general area. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel. Refer to http://www.lincolnelectric.com/safety for additional safety information.
PATENT INFORMATION Patent Pending Product Name Description SPECIFICATIONS Cool-Shield 5x4 ADF Variable Shade ADF Shade 9-3 LCD Size W x H mm inch 94 x 35 3 3/4 x 3/8 ADF Range Light State Sensitivity Delay Modes Sensors Light to Dark Dark to Light TIG Amps 9,0,2,3 3 Fixed --- 2 0. ms 0.2 s 50 amps Compliance () ANSI Z87., CSA Z94.3 () Headgear compliance with ANSI Z87. is without sweatband installed. 2
OPERATING INSTRUCTIONS Headgear Adjustment Head Size Adjustment: HEADGEAR TIGHTNESS is adjusted by pushing in the Ratchet Knob and turning to adjust for the desired head size. This knob is located at the back of the helmet. HEADGEAR CROWN ADJUST- MENT is made by adjusting for comfort and snapping the pin into the hole to lock securely in place. Tilt: Tilt adjustment is located on left side of helmet. Loosen the left headgear tension knob and push the top end of the adjustment lever inward until the lever s Stop Tab clears the notches. Then rotate the lever up or down to the desired tilt position. The Stop will automatically engage again when released locking the helmet into position. Fore / Aft Adjustment: Adjusts the distance between user s face and lens. To adjust, loosen both outside tension knobs and slide forward or back to desired position and retighten. NOTE: Make sure both sides are equally positioned for proper operation. Battries: No batteries are required! This product is solar powered and contains solar panels. CAUTION: Insure the solar panels are facing forward toward the outside of the helmet to capture light from the welding arc and surrounding environment. 3
AUTO-DARKENING CARTRIDGE CONTROLS COOL-SHIELD - 4 x 5 ADF include Variable Shade Only. To make adjustments to your ADF controls, push directly on the clear protective lens surface in the area over the shade control button. There is no need to disassemble helmet to access control buttons on your ADF cartridge. Simply press directly on the inside cover lens to change button settings. Shade selection is accomplished by pushing the Shade button on the back of the filter. Follow shade selection chart (page 5). Test your ADF filter prior to welding by directing the front of the filter toward a bright source of light, then using your fingers rapidly cover and uncover the sensors. The filter should darken momentarily as the sensor is exposed. A torch striker can also be used. 4
SHADE GUIDE: GUIDE FOR SHADE NUMBERS OPERATION ELECTRODE SIZE ARC MINIMUM SUGGESTED() /32 in. (mm) CURRENT (A) PROTECTIVE SHADE NO. SHADE (COMFORT) Shielded metal arc Less than 3 (2.5) Less than 60 7 welding 3-5 (2.5 4) 60-60 8 0 5-8 (4 6.4) 60-250 0 2 More than 8 (6.4) 250-550 4 Gas metal arc Less than 60 7 welding and flux 60-60 0 cored arc welding 60-250 0 2 250-500 0 4 Gas tungsten arc Less than 50 8 0 welding 50-50 8 2 50-500 0 4 Air carbon (Light) Less than 500 0 2 Arc cutting (Heavy) 500-000 4 Plasma arc welding Less than 20 6 6 to 8 20-00 8 0 00-400 0 2 400-800 4 Plasma arc cutting (2) (Light) Less than 300 8 9 (2) (Medium) 300-400 9 2 (2) (Heavy) 400-800 0 4 Torch brazing 3 or 4 Torch soldering 2 Carbon arc welding 4 PLATE THICKNESS in. mm Gas welding Light Under /8 Under 3.2 4 or 5 Medium /8 to /2 3.2 to 2.7 5 or 6 Heavy Over /2 Over 2.7 6 or 8 Oxygen cutting Light Under Under 25 3 or 4 Medium to 6 25 to 50 4 or 5 Heavy Over 6 Over 50 5 or 6 () As a rule of thumb, start with a shade that is too dark, then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding or cutting where the torch produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line the visible light of the (spectrum) operation. (2) These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece. Data from ANSI Z49.-2005 If your helmet does not include any one of the shades referenced above, it is recommended you use the next darker shade. WARNING DO NOT WELD WITH A DAMAGED OR DEFECTIVE LENS, i.e. cracked, pitted, etc. ALWAYS TEST TO BE SURE THE ADF CARTRIDGE IS CHARGED BEFORE WELDING. The helmet can be placed in sunlight to charge. Do not store the helmet in a dark cabinet or other storage area for extended periods. While welding the Arc also charges the ADF cartridge. 5
LENS REPLACEMENT Outside Protective Cover Lens Replacement: Press down on the Tab inside the top of the helmet while also pressing in on the Finger Tabs on both sides of the bezel piece on the front of the helmet. Pull the bezel outward to remove. Remove the polycarbonate protective lens. Place the new polycarbonate lens in the recessed lens area. Be sure the cover lens is properly seated. Then, simply insert the lower tabs of the bezel back into the helmet shell and rotate up, snapping the bezel into place. Ensure all three tabs have been correctly snapped in. Never use the Auto- Darkening FILTER without the inside and outside cover lens properly installed. INSIDE TAB Lens Removal BEZEL OUTSIDE TAB OUTSIDE TAB 6
AUTO-DARKENING CARTRIDGE ACCESS AND REPLACEMENT: Remove the Bezel as described in previous section on Lens Replacement. After removing the outside lens, simply remove the Adaptor by applying thumb pressure to top center tab to release top portion of Adaptor. Pull forward and release feet of Adaptor from Shell. Then remove the ADF filter. When replacing, be sure the light sensors are facing toward the front of the helmet when replacing the cartridge. Replace the inside cover lens, Cartridge, Adaptor, outside spatter lens and Bezel in reverse order. The outer polycarbonate lens is required to protect the ADF from weld spatter and impacts. 7
INSTALLING AN AFTERMARKET MAGNIFYING LENS: Simply slide the magnifying lens into the short rails located over the protective cover lens. Virtually maintenance free: Storage: HELMET CARE AND MAINTENANCE: Periodic cleaning with soapy water solution or standard glass cleaner is suggested for any ADF to function properly. Use soft cloth or eye glass wipes. This ADF is water resistant. Do NOT submerge in water or other solution. Change or clean cover lens when it becomes dirty or cloudy. Store in a clean dry location. 8
TROUBLE SHOOTING GUIDE: Test your ADF filter prior to welding by directing the front of the filter toward a bright source of light, then using your fingers rapidly cover and uncover the sensors. The filter should darken momentarily as the sensor is exposed. A torch striker can also be used. Difficult to see through the filter: Clean or replace protective cover lenses. Clean the Auto-Darkening cartridge by using a cloth with soapy water solution or standard window cleaner. The ADF will not darken after striking an arc: Avoid blocking the Solar Panels. Must be facing forward (outside of) in the helmet. Test the ADF by exposing to a bright light source and run your fingers quickly over the arc sensors. The filter should darken momentarily then switch back to the light state. Slow to darken: If the filter has not been used for a day or more, the circuitry will enter a sleep mode. It will wake up when tested or when you begin welding. Note that the first time, it may darken to a lighter shade even though set for a darker shade. After the first time, it will darken to the correct shade setting every time. It is recommended to test your ADF prior to welding. Colder temperatures can slow the switching speed of any ADF. Once the helmet warms up from the welding process, the switching will increase to rated speeds. ADF (Auto-Darkening Filter Cartridge) flickers or returns to light state while welding: Clean or replace protective cover lenses if dirty or cloudy. Check that the solar panels or sensors are not damaged or dirty. Clean with a soft cloth and soapy water solution or standard glass cleaner. Do not use abrasive or dirty cloths. Make sure you are not blocking the sensors or solar panels with your arm or other obstacle (including the welding torch gun or nozzle) while welding. Adjust your position so that the sensors can see the weld arc. 9
ADF stays dark after you stop welding: The temperature limitations of the ADF have been exceeded. Let the ADF cool down and try not to over heat it again by viewing the arc from the side or at a greater distance. It may remain dark if you are facing a bright light or the sun. Look away or pass your hand between the sensor and light source. ADF is cracked: Cease (STOP) using this product if this problem exists. UV/IR protection may be compromised resulting in burns to the eyes or skin. Weld Spatter is Damaging the ADF: Missing, damaged, broken, cracked or distorted Protective Cover Lens. Replace inside and outside Clear Cover Lenses as needed. WARNING Do not use this product if severe spatter damage has occurred to the Auto-Darkening Filter Cartridge or protective clear cover lens. Severe eye damage and burns can result. ------------------------------------------------------------------------------------------------------ WARRANTY INFORMATION: WARRANTY: These helmets are warranted for a period of two years. Please contact us at (800) 833-9353 for any service or warranty questions. SPATTER DAMAGE IS NOT COVERED BY WARRANTY: Do not use this product without the correct protective clear cover lenses installed properly on both sides of the Auto-Darkening Filter cartridge (ADF). The cover lenses supplied with this helmet are properly sized to work with this product and substitutions from other suppliers should be avoided. 0
REPLACEMENT PARTS ITEM PART No. DESCRIPTION QTY. 2 3 4 5 6 7 8 Note Note Note KP2796- M2088-4 KP2759- L382 KP208-5B 5x4 SHELL, BLACK ADAPTOR BEZEL, BLACK CLEAR POLYCARBONATE LENS ADF 9-3 SHADE CARTRIDGE COOLSHIELD RATCHET HEADGEAR (INCLUDING SWEATBAND) ADJUSTMENT LEVER SWEATBAND (NOT SHOWN) Note : Contact Lincoln Electric Service for appropriate replacement parts. 2 HEADGEAR 7 ADJUSTMENT LEVER 6 INSIDE LENS KNOB 6 ADF ADAPTOR OUTSIDE LENS BEZEL SHELL 4 5 2 4 3
World's Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland, Ohio 447-99 U.S.A. TEL: 26.48.800 FAX: 26.486.75 WEB SITE: www.lincolnelectric.com