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OM-240 362B

2008−11

Expert Series Auto-Darkening Helmets

Model: XVX

For more information, visit www.HobartWelders.Com

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS −READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 2 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 3 − OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

3-2. Reset Button And Low Battery Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3-3. Lens Delay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3-4. Variable Shade Control (No. 9 − 13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3-5. Sensitivity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 4 − ADJUSTING HEADGEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SECTION 5 − REPLACING THE LENS COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5-1. Replacing Outside Lens Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5-2. Replacing Inside Lens Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 6 − REPLACING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SECTION 11 − LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 1 − SAFETY PRECAUTIONS −

READ BEFORE USING

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous

. Indicates special instructions.

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.

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. Hazards

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.

DWear 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 in Sections 3-4

and 3-5.

D Wear approved safety glasses with side shields under your helmet.

D Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

DWear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.

WELDING HELMETS do not provide unlimited eye, ear and face protection.

D Use impact resistant safety spectacles or goggles and ear protection at all times when using this welding helmet.

D Do not use this helmet while working with or around explosives or corrosive liquids.

DDo not weld in the overhead position while using this helmet.

DInspect 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.

D Wear approved ear protection if noise level is high.

SECTION 2 − SPECIFICATIONS

Viewing Field

97 x 60mm/3.875 x 2.375 in

Reaction Time

0.0000500sec (1/20,000)

Available Shades

Darkened State: No. 9 − No. 13 / Light State: No. 4

provides continuous UV and IR protection

Sensitivity/Grind Mode Control

Adjusts for varying ambient light and welding arc

Delay Control

Slows lens dark-to-light state between 0.1 and

1.0 seconds

Automatic Power Off

Shuts lens Off 15−20 minutes after last arc is struck

Low Battery Indicator

Red LED light illuminates to indicate 2−3 days

remaining battery life

Power Supply

CR2450 Lithium Batteries (Hobart Part No. 770 284)

Sensors

Independent/Redundant (Four)

Operating Temperature

14_F to 131_F / −10_C to +55_C

. When stored in extremely cold temperatures, warm

helmet to ambient temperature before welding.

Storage Temperature

−4_F to 158_F / −20_C to +70_C

. When stored in extremely cold temperatures, warm

helmet to ambient temperature before welding.

Total Weight

510.3 g (1 lb 2oz)

Standards

ANSI Z87.1-2003 and DIN/CSA/TUV

Warranty

2 years from date of purchase (see Section 11)

.The helmets in this manual are covered by one or more of the following patents:

U.S. Patent − No. 6,552,316, No. 6,483,090, No. 6,614,409 U.S. Patent Application − No. 29/223,100, No. 11/053,977

DE. Patent − No. 199 59 944 C2, No. 199 59 945 C2 FR. Patent − No. 9916004

SECTION 3 − OPERATING INSTRUCTIONS

3-1. Helmet Controls

1

Reset Button (See Section 3-2)

2

Low Battery Indicator

(See Section 3-2)

3

Variable Shade Control (See

Section 3-4)

4

Sensitivity Control

(See Section 3-5)

1

2

3

4

5

5

Lens Delay Control

(See Section 3-3)

804 847

3-2. Reset Button And Low Battery Indicator

. The auto-darkening lens turns on

(darkens) automatically when welding begins and turns off 15 −

20 minutes after welding stops.

1

2

1

Reset Button

Press Reset button to check if the lens

is working properly.

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 de-

scribed. (See Section 9, Trouble-

shooting.)

2

Low Battery Indicator

The low battery indicator lights when

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2−3 days of battery life remain.

If battery power is low, replace with

CR2450 lithium batteries (2 required)

(Hobart Part No. 770 284) (see Section 6).

3-3. Lens Delay Control

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.

1

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.).

3-4. Variable Shade Control (No. 9 − 13)

1 Variable Shade Control

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(No. 9 − 13)

Use the control to adjust the lens shade in the darkened state. Use the table below to select proper

1 shade control setting based on your welding process.

Start at shade 12 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

9

40−80

10

80−175

11

175−300

12

300−500

13

MIG

Less than 100

10

100−175

11

175−300

12

300−500

13

Gas Tungsten Arc Welding

Less than 50

10

(TIG)

50−100

11

100−200

12

200−400

13

Air Carbon

Less than 500

12

500−700

13

Plasma Arc Cutting

60−150

11

150−250

12

250−400

13

Plasma Arc Welding

Less than 50

9

50−200

10

200−400

12

3-5. Sensitivity Control

1

Sensitivity Control

Weld Mode

Use control to make the lens more respon-

sive to different light levels in various weld-

ing processes. Use a Mid-Range or

1

30−50% sensitivity setting for most ap-

plications.

It may be necessary to adjust helmet sensi-

tivity to accommodate different lighting con-

ditions or if lens is flashing On and Off. Ad-

just

helmet sensitivity as follows:

. Adjust helmet sensitivity in lighting con-

ditions helmet will be used in.

S

Turn sensitivity control to lowest

setting.

S

Press Reset button to turn helmet On.

Helmet lens will darken twice and then

clear.

S

Face the helmet in the direction of use,

exposing it to the surrounding light con-

ditions.

S

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 con-

trol 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)

SECTION 4 − ADJUSTING HEADGEAR

. 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 bal-

1

ance and stability.

3

2

Headgear Tightness

To adjust, push in the adjusting knob

located on the back of the headgear

and turn left or right to desired tight-

ness.

. If adjustment is limited, it may be

necessary to remove the com-

fort 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 de-

sired position and retighten. (Both

sides must be equally positioned for

proper vision.)

4

Angle Adjustment

2

4

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 ten-

sion adjustment knob then lift on the

control arm tab and move it to the de-

sired position. Retighten tension ad-

justment knob.

. When using the back distance

adjustment positions, only the

back three angle adjustment

pins can be used.

804 118

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

2

1

2

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

cover gasket faces the lens cov-

er holder.

Be sure flat side of gasket faces lens cover holder.

4

3

8804 814 / 804 816

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 Lens Assembly

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2 inside Lens Cover

Remove the lens cover holder (see

Section 5-1). Remove lens assembly.

Remove the inside lens cover by prying the cover up at either thumbnail opening at each side of the cover.

Slide cover it out of either side of frame. Replace lens cover and reinstall the assembly in the helmet by reversing the above procedure.

. Be sure the cover lens is seated properly (flat) to prevent fogging.

1

2

SENSITIVITY

DELAY

1

804 817 / 804 818

SECTION 6 − REPLACING THE BATTERY

To replace the batteries, remove the auto-darkening lens assembly (see Section 5).

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 (Hobart Part No. 770 284).

. 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.

Be sure Positive (+) side of battery faces up.

+

+

1

804 847

SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS

1 Optional Magnifying Lens

Starting at the bottom, slide magnifying lens into the helmet retaining brackets. Align the magnifying lens with the auto-darkening lens assembly.

D Remove lens holding frame (with auto-darkening lens) from helmet shell.

D Remove auto-darkening lens from lens holder.

D Position lens holder with magnifying lens holding tabs facing toward you.

From the bottom up, slide magnifying lens into position. (Slide magnifying lens up or down slightly as desired.)

1

D Reinstall the auto-darkening lens in the lens holder.

D Reverse procedure to remove magnifying lens.

. To prevent lens fogging, install

flat side of magnifying lens toward auto-darkening lens.

804 818

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 – auto-

Check batteries and verify they are in good condition and installed

lens will not darken mo-

properly. Also, check battery surfaces and contacts and clean if

mentarily when the Reset

necessary. Check battery for proper contact and gently adjust

button is pressed.

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.

Not switching – auto-lens

Stop welding immediately: Press the Reset button if lens is Auto-

stays light and will not

On type. If lens if Manual-On type, make sure the lens is turned

darken when welding.

On. If power is on, review the sensitivity recommendations and

adjust sensitivity. Clean lens cover and sensors of any obstruc-

tions. Make sure the sensors are facing the arc; angles of 45_ or

more may not allow the arc light to reach the sensors.

Not Switching – auto-lens

Fine-tune the sensitivity setting by making small adjustments to

stays dark after the weld

the control by turning it toward the “min” setting. In extreme light

arc is extinguished, or the

conditions, it may be necessary to reduce the surrounding light

auto-lens stays dark when

levels.

no arc is present.

Sections of the auto-lens

Stop welding immediately: The auto-lens may be cracked which

are not going dark, distinct

can be caused by the impact of dropping the helmet. Weld spatter

lines separate the light and

on the auto lens may also cause cracking. (The lens may need to

dark areas.

be replaced; most cracked lenses are not covered by warranty).

Switching or Flickering –

Review the sensitivity setting recommendations and increase the

the auto-lens darkens then

sensitivity if possible. Be sure the arc sensors are not being

lightens while the welding

blocked from direct access to the arc light. Check the lens cover

arc is present.

for dirt and spatter that may be blocking the arc sensors. Increas-

ing Lens Delay 0.1 − 0.3 second may also reduce switching.

Inconsistent or lighter

Referred to as an angle of view effect, auto-darkening lenses

auto-lens shading in the

have an optimum viewing angle. The optimum viewing angle is

dark-state, noticeable on

perpendicular or 90_ to the surface of the auto-lens. When that

the outside edges and cor-

angle of view varies in the dark-state, welders may notice slightly

ners.

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.

SECTION 10 − PARTS LIST

2

1

5

3

4

6

804 814

Figure 10-1. Prowler Auto-Darkening Welding Helmet

Item

Part

Description

No.

No.

Quantity

Figure 10-1. Prowler Auto-Darkening Welding Helmet

1 . . . . . . . .

770613 . . . .

Ratchet Headgear Assembly (Does Not Include Item 2) . . .

. . . . 1

2 . . . . . . . .

770616 . . . .

Comfort Cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 1

3 . . . . . . . .

770274 . . . .

Diopter Lens 150X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 1

. . . . . . . . . .

770275 . . . .

Diopter Lens 175X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 1

. . . . . . . . . .

770276 . . . .

Diopter Lens 200X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 1

. . . . . . . . . .

770277 . . . .

Diopter Lens 250X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 1

4 . . . . . . . .

770612 . . . .

Cover Lens (Includes Front Lens Cover Gasket, . . . . . . . . . . . . . 1

Front Lens Covers, 2 Inside Lens Covers)

5 . . . . . . . .

770614 . . . .

Auto-Darkening Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 1

. . . . . . . . . .

770284 . . . .

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

. . . . 2

6 . . . . . . . .

770615 . . . .

Front Lens Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 1

SECTION 11 − LIMITED WARRANTY

Effective January 1, 2008

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 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.

Visit our website at www.HobartWelders.com

Hobart Welders

1635 West Spencer Street

Appleton, WI 54914 USA

Phone: 800-332-3281

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