ArcOne Singles S540-X Operator's manual

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Tel: [phone] Toll Free: [phone] Fax [phone] M-ADFilters-2004

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Table of Contents Page
Operation and Comfort 1
Preparations for Use 1-2
Technical Information 2-3
Single Shade Filters 3
Variable Shade Filters 3-4
Maintenance 5
Spatter Protection 6
Shade Selection Guide 7
Filter Specifications 8
Parts Selection Guide 9
Exploded Views 10-11
Trouble Shooting Guide 12-13
Warranty and Service Information 14
Operation and Comfort
As soon as you strike an arc, your new ARCONE®welding filter will automatically
darken. Our advanced optical detection system monitors your welding process to
ensure that your filter remains in the dark state in a wide range of arc-welding
applications. Protection from harmful ultra-violet / infrared radiation is always present
whether in the light or dark state.
Your new filter energizes automatically as soon as the arc is struck. All models are
solar powered so there are no on / off switches. There are no alkaline batteries to
change and no corrosion caused by leaky batteries. All ARCONE®products have a
lithium battery back up that supports the solar panels to ensure delay free operation
even in totally dark conditions.
Your new filter is capable of working in virtually all arc-welding applications. The arc
detection system is designed to detect an electronic welding arc and filter out other
sources of light. ARCONE®welding filters are not designed for oxy-acetylene, laser, or
very low amperage welding applications. It is virtually impossible to be specific as to
how low an amperage the sensors can detect. Every welding application is different
and there are other factors that may effect operation such as distance from the arc,
welding frequency, electrode type, shielding gasses, and lighting conditions (see Table
1).
We also know the importance of comfort. Our welding helmets are not only engineered
for safety and functionality but also for comfort. We have fully adjustable headgear that
is very comfortable and virtually indestructible. ARCONE®offers many different helmet
designs with many different styles and features. Whether you choose our lightest and
extremely durable nylon Hawk helmet or our reinforced fiberglass Falcon helmet you
will appreciate the noticeable difference our many designs offer (see table 3).
Preparations for Use
Before you begin welding always inspect your helmet and filter to ensure they are not
damaged. Check to see if the filter protection plates are clean, clear, and securely
attached to the helmet and covering the auto-darkening filter both front and rear.

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Preparations for Use (continued)
WARNING, never begin welding without first checking to see if the correct front
and rear protection plates are in place (see table 7 for part numbers). Failure to
protect your welding filter may cause damage and subsequently become a safety
hazard should the UV/IR protection be compromised from spatter or cracked
from impact. This type of damage is due to poor maintenance and/or abuse and
will void warranty.
The ratchet headgear is fully adjustable at both the brow and crown. While placing the
helmet on your head, push in and turn the adjusting knob on the ratchet headgear to
ensure a comfortable fit. The ratchet is designed to lock in place when released. The
height of the helmet can be adjusted by increasing or decreasing the length of the
crown strap. When making this adjustment remember to line your eyes up as centrally
to the viewing area as possible. Proper alignment enables the best view possible.
To test your f fi il lt te er r, prior to welding, direct the front of the filter to a bright source of light
then, using your fingers, rapidly cover and uncover the sensors. The filter will darken
momentarily. Another means of testing is to utilize a torch striker or TV or VCR remote.
These devices will also momentarily darken the filter. Once you are sure that the filter is
working properly you are now ready to begin welding.
WARNING, other safety precautions such as protective clothing, adequate
ventilation, breathing protection (such as a Compact Air PAPR or equal), fire
extinguisher, and protection for co-workers, should also be considered.
Technical Information
Passive welding filters have consistent shade darkness throughout the filter. The
shading of a passive filter remains constant even when viewed at an angle to the filter’s
surface. Auto-darkening filters utilize a shutter type of LCD to decrease light
penetration when energized. All electronic welding filters exhibit a characteristic known
as angle dependency. This characteristic may make the lens appear to be darker in the
center and lighter toward the outer edges when the lens is viewed at an angle not
perpendicular to the filter’s surface or not perpendicular to the arc (see Figure 1).
(Figure 1)

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Technical Information (continued)
ARCONE®auto-darkening filters protect the user against harmful ultra-violet and infrared
rays, both in the dark and light state. No matter what shade the filter is set to, the UV/IR
protection is always there. You can never burn your eyes due to optical radiation
passing through the filter. The users eyes can be severely burned if he welds with a
damaged lens (cracked, pitted, etc.) or optical radiation can possibly enter in from
behind as a result of other welders in the immediate area.
ANSI defines all welding helmets as secondary eye protection from optical
radiation and impact. For complete safety, primary protection, such as
spectacles or goggles, should be used in conjunction with welding helmets.
Protective clothing and accessories such as leather bibs attached to the welding
helmet will protect the user from spatter and optical radiation indirectly entering
from areas behind the helmet.
ACGIH (American Conference of Governmental Industrial Hygienists) has
established a TLV-TWA of 5mg/m3 for welding fumes. Welding fumes cannot be
classified simply. The composition and quantity of both are dependent on the
alloy being welded and the process and electrodes used.
Digitally Controlled Variable Filters: Press (do not hold) the Select button, an LED
will indicate the current setting. Press and hold the button to change the setting (see
figure 2).
Figure 2: Digital Controls
Analog Controlled Variable Filters: manually control shade and sensitivity with the
knob located on the outside of the helmet (see figure 3).
Figure 3: Analog Controls
LOW
HIGH
FAST SLOW LED
PUSH BUTTONS
SENSITIVITY
DELAY
PUSH BUTTON
DELAY TIG
12 11 10 9
LED
Select
Shade
Adjustmen
t
Sensitivity
A
djustment (where
applicable)

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Single Shade Filters
Singles ®, Super Singles 240™, XT ™, and Xtreme™ (X450F & X540F) models are
single shade auto-darkening welding filters. This means that when the arc is struck the
lens automatically darkens to a specific predetermined shade.
•The
XT
®
is available in a dark shade of 10 with a light shade of 2.5
(see table 5).
•
• The
Singles
®
is available in 4 different dark shades. Shades 9, 10, and 11 are
available with a light shade of 2.5 and shade 12 is available with a light shade of 3
(see table 5).
•The
Super Singles 240™ is available in a dark shade of 10.5 with a light state of
2.5 with a sensitivity and delay mode for TIG welding and a power off mode for
grinding (see table 5).
•The Xtreme™ X450F and X540F are available in a dark shade of 10.5 with a
light shade of 2.5 with a sensitivity and delay mode for TIG welding and a power
off mode for grinding (see table 5).
Variable Shade Filters
• Industrial Xtreme™ has a knob, located on the outside of the helmet, which can
be rotated to decrease or increase the shade level 7-14, without the need to
remove the helmet or gloves along with sensitivity and grinding adjustment. An
on/off mode specifically designed to maintain the light state when grinding and set
delay from dark to light (see table 6).
•The
Industrial ™ has a knob located on the outside of the helmet, which can be
rotated to decrease or increase the shade level, without the need to remove the
helmet or gloves. The I450 and I540 has a shade selection 7 to 14 and the I240
has a shade selection 9-13. Both with a light state of 3 (see table 6).
•The
Xtreme™ (X450V and X540V) filters have a button on the filter which allow
you to easily change shades from 9 to 12 with a light state of 3. There is a heads-
up display located above the viewing area, which allows the welder to quickly see
the current shade and an on/off mode specifically designed to maintain the light
state when grinding (see table 6).
•The
Shades™ 450 and 540 filters have a button on the filter which allows you to
easily change shades from 9 to 12 with a light state of 3. There is a heads-up
digital display at the bottom of the inner viewing area, which allows the welder to
quickly see the current shade and mode (see table 6).
Sensitivity and Delay adjustments (Super Singles 240™,
Xtreme™, Shades, and Industrial™450 and 540, and Industrial
Xtreme™ Filters Only)
In addition to adjusting the shade level, these filters have the ability to change the arc
detection sensitivity from the general welding mode to a more sensitive TIG welding
mode. A delay mode is also included and is typically on when performing most welding
applications except spot welding. When the delay mode is off, or on fast, the filter
switches quickly from the dark shade to the light shade and slower when the delay
mode is in the “on” or “slow” position. When spot welding, the delay mode is off, or on
fast, allowing the user to quickly move from one weld to the next without having to wait
for the filter to lighten in order to see his next target. The delay mode is utilized for
longer duration welds where the slower switching time, from the dark shade to the light
shade, allows the weld puddle to cool and darken further reducing the glare to the
welder’s eye (see table 1).

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Recommended Welding Application (Table 1)
Welding Application “Heads Up” Display as seen by user
SMAC, MIG, TIG, 40 amps and above Delay 9, 10, 11, or 12
SMAC, MIG, TIG, 30 amps and above Delay TIG 9, 10, 11, or 12
Spot welding, 40 amps and above 9, 10, 11, or 12
Spot welding, 30 amps and above TIG 9, 10, 11, or 12
Note: The above settings are meant to illustrate which welding applications are
suggested for each configurable mode. Applications vary greatly so please
experiment with the many available setting combinations in order to find the best
combination of shade level, sensitivity and delay for your personal comfort and
performance efficiency.
Grinding Mode
Super Singles 240: press and hold grind/delay until LCD flickers to
indicate the change to grind mode. Press (DO NOT HOLD) and release
again to turn off (LCD will not flicker).
Xtreme X540F & X450F: press and hold sensitivity button until
“standard” LED flashes. Press (DO NOT HOLD) and release again to
turn off (LCD will not flicker).
Xtreme X540V & X450V: Press and hold grinding button until the LCD
flickers to indicate the change to grind mode. Press (DO NOT HOLD)
again to turn off (LCD will not flicker).
Industrial 540 & 450: Turn the sensitivity knob located on the outside of
the helmet clockwise to the lowest setting. This setting will work with
most grinding applications. If this setting is not low enough, press and
hold the delay/grind button until the LCD flickers. Press (DO NOT
HOLD) again to turn off (LCD will not flicker).
Industrial Xtreme: Turn the sensitivity knob located on the outside of
the helmet clockwise to the lowest setting. This setting will work with
most grinding applications. If this setting is not low enough, press and
hold the delay/grind button until the LCD flickers. Press (DO NOT
HOLD) again to turn off (LCD will not flicker).
Recommended Welding Amperage Ranges (Table 2)
(The recommended range is based darkest shade available for the particular filter model)
Filter Model Shade Recommended
Range
Singles®240, 450, and 540 12 40 to 250
XT®450 and 540 10.5 40 to 200
Super Singles 240™, Xtreme™ 450F and 540F 10.5 30 to 210
Xtreme™ 450V and 540V 12 30 to 250
Shades™ 450 and 540 12 30 to 250
Industrial ™ 240 13 35 to 250
Industrial ™ 450 and 540 14 35 to 300
Industrial Xtreme™ 14 30 to 300
The recommended ranges stated above are to be used as a guideline. Lower
welding amperages may be achieved and are directly influenced by the
application. Upper range amperages can vary based on the comfort level that the
user requires. Caution: Do not exceed the filter temperature range (–14 to 148
degrees F)

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Welding Helmets (Table 3)
Eagle®
(0200)
Hawk®
(0300)
Falcon™
(0400)
Vision®
(0500)
Hiderok
(
0600
)
Viper
(
0900
)
Material Nylon Nylon Fiberglass Nylon Thermal
Plastic Nylon
Applicable
Filters
S
Si in ng gl le es s®
®450
X
XT T®
4 45 50 0
Shades™ 450
Industrial ™ 450
Xtreme ™ 450
S
Si in ng gl le es s®
®240
Super
Singles240™
Industrial ™ 240
S
Si in ng gl le es s®
®5
54 40 0
X
XT T®
5 54 40 0
S
Sh ha ad de es s
™
5 54 40 0
I
In nd du us st tr ri ia al l
™
5 54 40 0
S
Si in ng gl le es s®
®240
S
Si in ng gl le es s
™
™
540
Super Singles 240™
X
XT T® 5 54 40 0
Shades ™ 540
Industrial ™ 240
Industrial ™ 540
Xtreme ™ 540
S
Si in ng gl le es s®
®240 Xtreme
™ 540
Industrial ™ 540
I
In nd du us st tr ri ia al l X Xt tr re em me e™ ™
Weight
(ounces) 16.25 14.75 17.25 17.6 13.75
Usage All applications except
overhead
All applications
except overhead All applications All applications except overhead
All
applications
except
overhead
All applications
except overhead
Maintenance
Your new filter requires virtually no maintenance other than periodic cleaning when the
lens becomes dirty or clouded from smoke. ARCONE®
Auto-Darkening Filters are water-
resistant and may be cleaned by using a soft cloth with a soapy water solution, or
standard window cleaner. By changing cover plates frequently you will extend the life of
your filter and guarantee the best operation possible. Additional front and rear cover
plates are available from your ARCONE®distributor (see Table 7 for part numbers).
NOTE: Using the wrong cover plates may damage your product and VOID
WARRANTY . Use genuine ArcOne replacement parts to ensure quality and fit.
Special note for X XT T®
users:
The extended viewing area is made of highly polished optical material. It has been hard
coated with a scratch resistant finish. IT IS NOT SCRATCH PROOF! The raised area,
around the perimeter of the case, suspends the cover plates above lens surface
therefore protecting the polished areas from abrasion. Clean your XT™as directed.
Please be careful to use a soft clean cloth or eyeglass wipes. Abrasive particles in a
dirty cloth could scratch the polished surface. Install ArcOne cover plates on both sides
of the filter to protect from spatter damage and further scratching.
NOTE: To keep your
X
X
T
T®
free from scratches Please take care of it as if it were
your personal eye glasses or the paint job on your favorite car or motorcycle.
Spatter Protection
SPATTER DAMAGE IS NOT COVERED BY WARRANTY
There are many reasons why spatter can damage the Auto-Darkening Filter. Missing,
incorrect, damaged, or distorted cover plates, and excessive spatter build-up in and
around the areas where the cover plates are retained are just a few examples. Any one or
combination of these will allow spatter to enter the filter area and pit the filter glass.

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Spatter Protection (continued)
The Hawk®and Eagle®take a special 0.040” thick cover plate.
Using a nominal 0.060” cover plate will not work in this design.
The Hawk®and Eagle®Helmets are designed to accept polycarbonate cover plates
from the outside of the helmet without removing other components. This design
allows for quick and easy cleaning and cover plate replacement. The use on an
incorrect cover will distort the helmet and result in spatter entering the filter area.
Please use only ArcOne 0.040” inch cover plates in these products.
NOTE, change your cover plate when it loses its flexibility and or becomes bowed
or distorted. Clean any build-up from the area where the cover plate is retained.
All other helmet designs, other than the Hawk®and Eagle®, will accept either a
0.040” or a 0.060’ cover plate. Flip front designs must use 0.060” thick inner cover
plates for protection from particles produced when chipping or grinding.
The Hawk®and Eagle®have been designed to accept an additional protective lens.
This additional lens installs immediately in front of the auto-darkening filter and
behind the outer polycarbonate clear lens thus adding an even greater level of
spatter protection.
Users with excessive spatter applications can rely on the greater protection
provided by this options. See information below.
Part Numbers for Intermediate Cover Plates
Helmet Model Part No.
Eagle (0200) 02-OP
Hawk (0300) 03-OP
ANSI Shade Selection Guide (Table 4)
Operation Arc Current Minimum Shade Comfort Shade
Stick (SMAW) < 60 7 ---
60 to 160 8 10
160 to 250 10 12
250 to 550 11 14
MIG (GMAW) <60 7 ---
60 to 160 10 11
160 to 250 10 12
250 to 500 10 14
TIG (GTAW) <50 8 10
50 to 150 8 12
150 to 500 10 14
Carbon Arc-light <500 10 12
Carbon Arc-heavy 500 to 1000 11 14
Plasma Arc (PAW) < 20 6 8
20 to 100 8 10
100 to 400 10 12
400 to 800 11 14
Plasma Cutting < 300 8 9
300 to 400 9 12
400 to 800 10 14
Carbon Arc (CAW) --- --- 14

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Single Shade Filter Specifications (Table 5)
S
Si in ng gl le es s®
®
240 S
Si in ng gl le es s®
®
450 & 540 S
Su up pe er r S Si in ng gl le es s
2
24 40 0™ ™X
XT T®
® 450 &
540 X
Xt tr re em me e ™ ™
450F & 540F
Viewing Area 1 3/8” by 3
¾”
5.25 sq. in.
1 3/8” by 3 ¾”
5.25 sq. in. 1 3/8” by 3 ¾” 5.25 sq. in. 1 3/8” by 3 ¾” 5.25 sq. in. 12.5 sq. in.
Total Expanding
Viewing Area N/A N/A N/A Approximately 20 square
inches
NA
Grinding Mode N/A N/A Yes N/A Yes
Filter Dimensions 2” by 4 ¼”
0.2” thick 4 ½” by 5 ¼” or 5 ¼” by 4 ½”
0.2” thick
2” by 4 ¼”
0.2” thick 4 ½” by 5 ¼” or
5 ¼” by 4 ½”
0.2” thick
4 ½” by 5 ¼”
or
5 ¼” by 4 ½”
0.246” thick
ARC Sensing 2 sensors 2 sensors 2 sensors 2 sensors 4 sensors
Sensitivity and delay N/A NA TIG and
Production N/A TIG and Production
Switching Time
Seconds 5/10,000 (0.5
milliseconds
)
5/10,000
(0.5 milliseconds) 5/10,000 (0.5
milliseconds)
5/10,000
(0.5
milliseconds)
1/10,000
(0.1
milliseconds)
Primary Power Solar Cells Solar Cells Solar Cells Solar Cells Solar Cells
Back-up Power Lithium
Battery Lithium Battery Lithium Battery Lithium Battery Lithium Battery
Operating / Storage
Temperature -14 to 148 degrees F -14 to 148 degrees F -14 to 148 degrees F -14 to 148 degrees F -14 to 148 degrees F
UV / IR Protection Up to
Shade 16 Up to Shade 16 Up to Shade 16 Up to Shade 16 Up to Shade 16
Dark to Light Delay 0.1 secs 0.1 sec 0. 1 and 2 secs. 0.1 secs 0.1 and 2 secs
Light Shade 2.5 32.5 32.5 2.5 2.5
Dark Shade 9, 10,
11 12 9, 10, 11 12 10.5 10.5 10.5
Certification ANSI Z87.1
- 1998 ANSI Z87.1 – 1998 ANSI Z87.1 – 1998 ANSI Z87.1 - 1998 ANSI Z87.1 - 1998
Variable Shade Filter Specifications (Table 6)
Xtreme ™
450V & 540V Shades™ 450 / 540 Industrial™ 240 Industrial™ 450 / 540 Industrial Xtreme ™540V
Viewing Area 3 7/8” x 1 5/8”
12.5 sq. in. 3 7/8” x 1 5/8” 6.35 sq. in. 1 3/8” by 3 ¾” 5.25 sq. in. 3 7/8” x 1 7/8” 7.35 sq. in. 3 7/8” x 1 5/8” 12.5 sq. in.
Grinding Mode Yes N/A N/A Yes Yes
Filter
Dimensions 4 ½”x5¼” or 5¼” x 4 ½”
0.246” thick
4 ½”x5¼” or 5¼” x
4 ½”
0.270” thick
2” by 4 ¼”
0.25” thick 4 ½” x 5¼” or 5¼” x 4 ½”
0.25” thick
5¼” x 4 ½”
0.312” thick
ARC Sensing 4 sensors 2 sensors 2 sensors 2 sensors 4 sensors
Sensitivity and
Delay Standard or TIG Standard or TIG Fixed Standard or TIG Standard or TIG
Switching Time
Seconds 1/10,000 (0.1 milliseconds) 1/10,000 (0.1 milliseconds) 1/10,000 (0.1 milliseconds) 1/10,000 (0.1 milliseconds) 1/10,000 (0.1 milliseconds)
Primary Power Solar Cells Solar Cells Solar Cells Solar Cells Solar Cells
Back-up Power Lithium Battery Lithium Battery Lithium Battery Lithium Battery Lithium Battery
Operating &
Storage Temp -14 to 148 degrees F -14 to 148 degrees F -14 to 148 degrees F -14 to 148 degrees F -14 to 148 degrees F
UV / IR Protection Up to Shade 16 Up to Shade 16 Up to Shade 16 Up to Shade 16 Up to Shade 16
Dark to Light
Delay 0.1 and 2 secs. 0.1 and 2 secs 0.1 secs 0.1 and 2 secs 0.1 and 2 secs
Light Shade 33334
Dark Shade 9 to 12 9 to 12 9 to 13 7 to 14 7 to 14
Certification ANSI Z87.1 - 1998 ANSI Z87.1 - 1998 ANSI Z87.1 - 1998 ANSI Z87.1 - 1998 ANSI Z87.1 - 1998

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PART SELECTION GUIDE – MAJOR COMPONENTS (TABLE 7)
Part Numbers And Descriptions
AUTO-DARKENING FILTERS
Eagle®0200 4 X 5 fixed front Hawk®0300 2 X 4 fixed front Falcon®400 5 X 4 fixed front Vision®0500 2 x 4 fixed front Vision®L500 2 x 4 flip front Vision®0500 5 x 4 fixed front Viper 0900™ 5 X 4 fixed front Hiderok 0600 2 X 4 fixed front Hiderok L600 2 X 4 flip front
Singles ® 240 (shade 9, 10, 11, or 12)     
Singles ® 450 (shade9, 10, 11, or 12) 
Singles ® 540 (shade9, 10, 11, or 12) 
SuperSingles™  
XT ™450 
XT ™540 
Xtreme™450 (X450F & X450V) 
Xtreme ™540 (X540F & X540V)  
Shades™450 
Shades ™540 
Industrial™240  
Industrial™450 
Industrial™540   
IndustrialXtreme™ 
HELMETSSHELLS
2-0200 black, 0210 silver, 0220 red 
3-0200 black, 0210 silver, 0220 red 
2-0300 black, 0310 silver, 0320 red 
3-0300 black, 0310 silver, 0320 red 
2-0400black, 3-0400,4-0400 
2-0500black, 0510silver, 3-0500black, 0510silver 
324-0600 black only 
324-L0600black only 
2-0900black, 3-0900black 
COVERPLATES
02-OP, Outside (4”x5”x0.040”)    
03-OP, Outside (2”x4”0.040”)     
SSIP, Inside (2”x4”0.040”)  
SMIP, Inside (4”x5”x0.040”)    
LF-IP, High impact for lift front models (2x4”x0.060”) 
SHADE UPGRADES #1 & #2
SMIP-1 and SMIP-2    
SSIP-1and SSIP-2     
HEADGEARand COMPONENTS
01-HG, Completeheadgear assembly 
03-HGSB Fatboy Sweat band 
04-HGSB Headgear Sweat band 
MISCELLANOUS CCOMPONENTS
SSML Magnifying Lens (1to2.5 power) (modified) 
VML Magnifying Lens (1to2.5 power) (standard) 
45ML Magnifying Lens with 4x5 adapter (1 to2.5 power) 
54ML Magnifying Lens with 5x4 adapter (1 to2.5 power)   
03-HH - Hard Hat with Adapter for Helmet 
03-HGHH Hard Had Adapter 
I-KAP,Shade Knob forIndustrialFilters W/O SETSCREW  