Lincoln Electric Welding System IM10001 User Manual

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IM10001  
February, 2009  
AUTO-DARKENING HELMET  
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 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
 
TABLE OF CONTENTS  
SAFETY WARNINGS – READ BEFORE USING  
HELMET INFORMATION  
Page  
1
2
3
4
5
6
7
8
9
9
SPECIFICATIONS  
OPERATING INSTRUCTIONS  
CARTRIDGE OPERATIONS/FEATURES  
SHADE GUIDE SETTINGS  
HELMET CARE AND MAINTENANCE  
TROUBLE SHOOTING  
WARRANTY INFORMATION  
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 pro-  
duce 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.  
for additional safety information.  
1
 
HELMET INFORMATION  
This Auto-Darkening Welding Helmet will automatically change from a light  
state (shade 3.5) to a dark state (Shade 9-13) when arc welding starts.  
The filter automatically returns to a light state when the arc stops.  
Shade control adjustments can be made while welding.  
Match your welding application to the shade indicated on the shade chart.  
(See Page 6)  
• Operating temperature: 14°F ~ 131°F  
(-10°C ~ 55°C).  
• Do not use or open the auto-darkening filter if damaged by shock, vibra-  
tion or pressure.  
• Keep the sensors and solar cell clean. Clean the filter cartridge using a  
soapy water solution and soft cloth which should be damp but not saturat-  
ed.  
This Auto-Darkening Welding Helmet is designed for use with GMAW, GTAW,  
MMAW welding, or Plasma Arc and air carbon arc cutting.  
The cartridge provides protection from harmful UV and IR radiation, in both  
dark and light states.  
The cartridge contains two sensors to detect the light from the welding arc,  
resulting in the lens darkening to a selected welding shade.  
• Do not use solvents or abrasive cleaning detergent.  
• If cover lens is spattered or covered with dirt, it should be replaced imme-  
diately.  
• Use only replacement parts specified in this manual.  
• Do not use the helmet without inside and outside cover lenses properly  
installed.  
2
 
SPECIFICATIONS  
LCD Viewing Area  
Cartridge size  
97 x 44mm (3.82 x 1.73in)  
110 x 90mm (4.33 x 3.54in)  
Up to Shade DIN 16 at all times  
2
UV/IR Protection  
Arc Sensors  
Light State Shade  
Variable Welding Shades  
Shade Control  
DIN 4  
DIN 9 to 13  
External knob - full adjustment  
Solar cells - no battery required  
Fully automatic  
Power Supply  
Power On/Off  
Light to Dark Switching Time  
Sensitivity Control  
0.00004 sec (1/25,000 sec)  
High (normal) and Low (extreme ambient light)  
Delay Control (Dark to Light) (0.25~0.35s <fast>)  
(0.60~0.80s<slow>)  
10 amps  
14°F ~ 131°F (-10°C ~ 55°C)  
TIG Rating  
Operating Temperature  
Storage Temperature  
Total Weight  
-4° ~ 158°F (-20°C ~ 70°C)  
440g (15.5 Oz.)  
Compliance(1)  
ANSI Z87.1-2003/CSA Z94.3  
(1)  
Headgear compliance with ANSI Z87.1 is without sweatband installed.  
3
 
OPERATING INSTRUCTIONS  
Headgear Adjustment  
HEAD GEAR  
FORE / AFT ADJUSTMENT  
TILT ADJUSTMENT  
CROWN  
ADJUSTMENT  
PIN HOLES FOR  
ADJUSTMENT  
RATCHET KNOB  
Head Size Adjustment: Headband tightness is adjusted by pushing in the  
ratchet knob and turning to adjust to desired comfort level. This knob is  
located at the back of the helmet. HEAD GEAR CROWN ADJUSTMENT is  
made by adjusting crown strap for vertical placement on the head and snap-  
ping the pin into the hole to lock securely in place.  
Tilt: Tilt adjustment is adjusted on both the left and right sides of helmet.  
TILT is adjusted by loosening outside tension knobs and releasing the adjust-  
ment lever from its current location and moving it to another location (one  
side at a time is recommended). Retighten the outside tension knobs when  
finished. NOTE: This adjustment location needs to be the same for the right  
and left side levers.  
Fore / Aft Adjustment: Fore/Aft adjustment is the distance between the  
user’s face and lens. To adjust, loosen the outside tension knobs to allow the  
bolts to be repositioned in a different location (one side at a time is recom-  
mended). NOTE: Make sure both sides are located the same for proper  
operation.  
4
 
CARTRIDGE OPERATION/FEATURES  
Variable Shade Control  
The shade can be adjusted from shade 9 to 13 based upon welding process or  
application (refer to Shade selection chart on page 6). The variable shade control  
knob is mounted to shell for external adjustment.  
Sensitivity Control  
You can adjust the light sensor by selecting the HIGH or LOW position of the  
sensitivity switch as shown in figure below. Generally, the HIGH setting is select-  
ed for normal use. Where the helmet is used in the presence of excess ambient  
light or with another welding machine close by, the LOW setting may be selected  
for better performance.  
Delay Time Control  
This control is designed to protect the welder’s eyes from the strong residual rays  
after welding. You can delay the time of change to light state from the darkened  
state with setting delay control switch on FAST or SLOW. The SLOW setting is  
recommended for high amperage applications where the weld puddle is still very  
bright after the welding arc has ceased and for situations where the filter may be  
temporarily blocked from seeing the welding arc.  
Solar Power  
This helmet is powered by solar energy. As such, there is no battery that requires  
replacement.  
SENSITIVITY  
HIGH  
DELAY TIME  
FAST  
SLOW  
LOW  
Variable shade  
control Knob  
5
 
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 long periods.  
While welding, the arc also charges the ADF cartridge.  
SHADE GUIDE SETTINGS  
GUIDE FOR SHADE NUMBERS  
(
)
1
OPERATION  
ELECTRODE SIZE  
1/32 in. (mm)  
ARC  
CURRENT (A)  
MINIMUM  
PROTECTIVE  
SHADE  
SUGGESTED  
SHADE NO.  
(COMFORT)  
Shielded metal arc  
welding  
Less than 3 (2.5)  
3-5 (2.5–4)  
Less than 60  
60-160  
7
8
10  
12  
14  
5-8 (4–6.4)  
160-250  
10  
11  
More than 8 (6.4)  
250-550  
Gas metal arc  
Less than 60  
60-160  
7
10  
10  
10  
welding and flux  
cored arc welding  
11  
12  
14  
160-250  
250-500  
Gas tungsten arc  
welding  
Less than 50  
50-150  
8
8
10  
12  
14  
150-500  
10  
Air carbon  
Arc cutting  
(Light)  
Less than 500  
500-1000  
10  
11  
12  
14  
(Heavy)  
Plasma arc welding  
Less than 20  
20-100  
6
8
6 to 8  
10  
100-400  
10  
11  
12  
400-800  
14  
(2)  
)
Plasma arc cutting  
(Light  
Less than 300  
300-400  
8
9
9
12  
14  
(Medium)(2)  
(Heavy)(2)  
400-800  
10  
Torch brazing  
3 or 4  
2
Torch soldering  
Carbon arc welding  
14  
PLATE THICKNESS  
in.  
mm  
Gas welding  
Light  
Under 1/8  
1/8 to 1/2  
Over 1/2  
Under 3.2  
3.2 to 12.7  
Over 12.7  
4 or 5  
5 or 6  
6 or 8  
Medium  
Heavy  
Oxygen cutting  
Light  
Under 1  
1 to 6  
Under 25  
25 to 150  
Over 150  
3 or 4  
4 or 5  
5 or 6  
Medium  
Heavy  
Over 6  
(1)  
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  
sodium line the visible light of the (spectrum) operation.  
the yellow or  
(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 Z49.1-2005  
If your helmet does not include any one of the shades referenced above, it is  
recommended you use the next darker shade.  
6
 
HELMET CARE AND MAINTENANCE  
Replacing Front Cover Lens: Replace the front cover lens if it is damaged  
– cracked, soiled or pitted. Place your finger or thumb into recess (C) at the  
bottom edge of the cover lens and flex the lens upwards until it releases from  
the edges marked A and B. (Refer to figure 1). Use only the replacement  
front cover lenses specified in this manual.  
Replace the Inside Cover Lens: if it is damaged (cracked, soiled or pitted).  
Place your fingernail in recess above cartridge view window and flex lens  
upwards until it releases from edges of cartridge view window.  
Change the Shade Cartridge (See figure 2)  
Fitting New Cartridge: Take the new shade cartridge and pass the poten-  
tiometer cable under the wire loop before placing the cartridge into its retain-  
ing frame inside the helmet. Hinge down the wire loop and ensure the front  
edge of the loop (D) is properly retained under the retaining lugs (E) as  
shown in (figure 3).  
Position the shade potentiometer to the inside of the helmet with the shaft  
protruding through the hole. Secure potentiometer to shell. On the outside of  
the helmet, push the shade control knob onto the shaft.  
Cleaning: Clean helmet by wiping with a soft cloth. Clean cartridge surfaces  
regularly. Do not use strong cleaning solutions. Clean sensors and solar cells  
with soapy water solution and a clean cloth and wipe dry with a lint-free cloth.  
Do NOT submerge shade cartridge in water or other solution.  
Storage: Store in a clean, dry location.  
Figure 1  
Figure 2  
Figure 3  
7
 
TROUBLE SHOOTING GUIDE  
Test your shade cartridge prior to welding by directing the front of the car-  
tridge toward a bright source of light, then using your fingers rapidly cover  
and uncover the sensors. The cartridge should darken momentarily as the  
sensor is exposed. A torch striker can also be used.  
PROBLEM  
POSSIBLE CAUSE  
SOLUTION  
Difficult to see through Front cover lens dirty.  
filter.  
Clean or replace front  
cover lens.  
Cartridge dirty.  
Clean the Auto-Darkening  
cartridge with soapy water  
solution and soft cloth.  
Filter does not darken Sensitivity is set on LOW. Set sensitivity to HIGH  
when arc is struck.  
Front cover lens dirty.  
Clean or replace front  
cover lens.  
Front cover lens is dam- Check for cracked or pit-  
aged.  
ted front cover lens and  
replace as required.  
Sensors are blocked or Make sure you are not  
Solar panel is blocked. blocking the sensors or  
solar panels with your  
arm or other obstacle  
while welding. Adjust your  
position so that the sen-  
sors can see the weld arc.  
Filter darkening with- Sensitivity set to HIGH. Set sensitivity to LOW  
out arc being struck.  
Filter remains dark after Delay time set to SLOW. Set delay time to FAST.  
completing a weld.  
WARNING  
ADF is  
cracked.  
Cease (STOP) using this product if this problem  
exists. UV/IR protection may be compromised  
resulting in burns to the eyes and skin.  
Weld spatter Missing, damaged,  
is damaging broken, cracked or  
Replace front cover lens  
as needed.  
the filter.  
distorted front cover  
lens  
8
 
WARRANTY INFORMATION  
WARRANTY INFORMATION: These helmets are warranted for a period of  
two years. Please contact us at 1 (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.  
REPLACEMENT PARTS  
4
HELMET  
SHELL  
3
1
2
ITEM  
PART NO.  
S27978-1  
S27978-5  
S27978-2  
S27978-3  
DESCRIPTION  
OUTSIDE COVER LENS  
ADF CARTRIDGE  
INSIDE COVER LENS  
HEADGEAR ASSEMBLY  
(INCLUDING SWEATBAND)  
SWEATBAND  
QTY  
1
2
3
4
1
1
1
1
5
S27978-4  
1
9
 

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