ESAB CIGWELD Arcmaster 649 Payday User manual

Version No: AA | Issue Date: 06-10-2022 | Manual No: 0-5658
AUTO-DARKENING
AUTO-DARKENING
Arcmaster Welding Helmet
Arcmaster 649 Payday, Part Number WHAM1649

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Cigweld product. We are proud to
have you as our customer and will strive to provide you with the
best service and reliability in the industry. This product is backed
by our extensive warranty and world-wide service network. To
locate your nearest distributor or accredited service provider call
[phone], or visit us on the web at www.cigweld.com.au
This Operating Manual has been designed to instruct you on the correct
use and operation of your CIGWELD product. Your satisfaction with this
product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions.
They will help you to avoid potential hazards that may exist when working
with this product.
We have made every effort to provide you with accurate instructions,
drawings, and photographs of the product(s) while writing this manual.
However errors do occur and we apologize if there are any contained in
this manual.
Due to our constant effort to bring you the best products, we may make
an improvement that does not get reflected in the manual. If you are ever
in doubt about what you see or read in this manual with the product you
received, then check for a newer version of the manual on our website
or contact our customer support for assistance.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
CIGWELD is the Market Leading Brand of Arc Welding Products for
ESAB. We are a mainline supplier to major welding industry sectors in
the Asia Pacific and emerging global markets including; Manufacturing,
Construction, Mining, Automotive, Engineering, Rural and DIY.
We distinguish ourselves from our competition through market-leading,
dependable products that have stood the test of time. We pride ourselves
on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales
and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment for industry operators.
Arcmaster Welding Helmet

!!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgement, the
Manufacturer assumes no liability for its use.
Auto-Darkening Welding Helmet
Instruction Manual Number 0-5658 for:
Arcmaster 649 Auto Darkening Welding Helmet (Payday) Part Number WHAM1649
Published by:
CIGWELD Pty. Ltd
71 Gower Street
Preston, Victoria, Australia, 3072
www.cigweld.com.au
Copyright 2022 by
CIGWELD
All rights reserved.
A reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss
or damage caused by any error or omission in this Manual, whether such error results from
negligence, accident, or any other cause.
Publication Date: 06-10-2022
Revision Date:
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Arcmaster Welding Helmet

Arcmaster Welding Helmet
Table of Contents
SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS................................5
1.01 Safety Instructions....................................................................................................5
1.02 Declaration of Conformity.........................................................................................7
1.03 Limited Warranty ......................................................................................................8
SECTION 2: INTRODUCTION ............................................................................... 10
2.01 How to Use This Manual.........................................................................................10
2.02 Equipment Identification.........................................................................................10
2.03 Receipt of Equipment..............................................................................................10
SECTION 3: GENERAL INFORMATION .................................................................... 10
3.01 Arcmaster Auto-Darkening Welding Helmet............................................................10
3.02 User Responsibility.................................................................................................10
SECTION 4: PERSONAL PROTECTION .................................................................... 11
SECTION 5: SPECIFICATIONS.............................................................................. 13
5.01 Arcmaster Auto-Darkening Filter Lens ....................................................................13
5.02 Contents .................................................................................................................13
SECTION 6: HARNESS ADJUSTMENT .................................................................... 14
SECTION 7: INSTALLATION OF MAGNIFICATION LENS (OPTIONAL)................................. 15
SECTION 8: CHANGING OF FRONT AND REAR COVER LENSES ...................................... 16
SECTION 9: ARCMASTER 649 AUTO-DARKENING FILTER LENS CONTROLS ....................... 16
SECTION 10: BATTERIES AND BATTERY COMPARTMENT ............................................. 17
SECTION 11: SPARE PARTS................................................................................ 18
SECTION 12: BASIC TROUBLESHOOTING................................................................ 19
Arcmaster Welding Helmet

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Arcmaster Welding Helmet
SECTION 1: Arc Welding Safety Instructions and Warnings
!
!
WARNING
ARC WELDING can be hazardous.
Protect yourself and others from possible serious injury or death. Keep children away. Do not lose these instructions. Read
operating manual before installing, operating or servicing this product.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety
rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this
equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Certain practices apply to equipment connected to power
lines; other practices apply to engine driven equipment.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides to what you should
learn before operating this equipment are listed at the end of these safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Safety Instructions
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns.
The electrode and work circuit is electrically live whenever the output
is on. The input power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding,
the wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Disconnect input power or stop engine before installing or servicing this
equipment. Lock input power disconnect switch open, or remove line fuses so
power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its Operating Manual
and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to equipment if it
will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay
it down on the ground or the work surface. Do not touch holders connected to
two welding machines at the same time or touch other people with the holder
or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground) circuit.
12. Use only well-maintained equipment. Repair or replace damaged parts at once.
13. In confined spaces or damp locations, do not use a welder with AC output
unless it is equipped with a voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor level.
15. Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense heat and strong
ultraviolet rays that can burn eyes and skin. Noise from some pro-
cesses can damage hearing.
1. Use a Welding Helmet or Welding Faceshield fitted with a proper shade of filter
(see ANSI Z49.1 and AS 1674 listed in Safety Standards) to protect your face
and eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and glare; warn
others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool
and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.

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Arcmaster Welding Helmet
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and
hot metal, weld spatter, hot work piece, and hot equipment can cause
fires and burns. Accidental contact of electrode or welding wire to
metal objects can cause sparks, over heating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material. Remove all
flammables within 35ft (10.7 m) of the welding arc. If this is not possible,
tightly cover them with approved covers.
3. Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
4. Watch for fire, and keep a fire extinguisher nearby.
5. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire
on the hidden side.
6. Do not weld on closed containers such as tanks or drums.
7. Connect work cable to the work as close to the welding area as practical to
prevent welding current from travelling long, possibly unknown paths and
causing electric shock and fire hazards.
8. Do not use welder to thaw frozen pipes.
9. Remove stick electrode from holder or cut off welding wire at contact tip when
not in use.
Flying sparks and hot metal can cause Injury.
Chipping and grinding cause flying metal. As welds cool, they can
throw off slag.
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged,
a cylinder can explode. Since gas cylinders are normally part of the
welding process, be sure to treat them carefuIIy.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks,
and arcs.
2. Install and secure cylinders in an upright position by chaining them to a
stationary support or equipment cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses and fittings designed
for the specific application; maintain them and associated parts in good
condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use or
connected for use.
8. Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
KEEP BATTERIES OUT OF REACH OF
CHILDREN
1. Swallowing may lead to serious injury in as little as 2 hours or death, due to
chemical burns and potential perforation of the oesophagus.
2. If you suspect your child has swallowed or inserted a button battery immediately
call the 24-hour Poisons Information Centre in Australia on 13 11 26 (or your
countries relevant Poison Information Centre) for fast, expert advice.
3. Examine devices and make sure the battery compartment is correctly secured,
e.g. that the screw or other mechanical fastener is tightened. Do not use if
compartment is not secure.
4. Dispose of used button batteries immediately and safely. Flat batteries can
still be dangerous.
5. Tell others about the risk associated with button batteries and how to keep
their children safe.

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Arcmaster Welding Helmet
1.02 Declaration of Conformity
Manufacturer: CIGWELD
Address: 71 Gower St, Preston
Victoria 3072
Australia
Description of equipment: Safety Equipment. CIGWELD Arcmaster Auto-Darkening Welding Helmet.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them are:
a. AS/NZS 1337.1:2010 Section 4 - Eye Protectors for industrial applications.
b. AS/NZS 1338.1:2012 Filters for Eye Protectors.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing
process, to ensure the product is safe and performs as specified. Rigorous testing is incorporated into the manufacturing process to
ensure the manufactured product meets or exceeds all design specifications.
CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance, ultra safe operation
and world class quality for more than 30 years and will continue to achieve excellence.

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Arcmaster Welding Helmet
1.03 Limited Warranty
LIMITED WARRANTY: CIGWELD Pty Ltd, CIGWELD An ESAB Brand, hereafter, “CIGWELD and/or ESAB” warrants to customers of its
authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should any failure to
conform to this warranty appear within the time period applicable to the CIGWELD/ESAB products as stated below, CIGWELD/ESAB
shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance
with CIGWELD/ESAB’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to
misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at CIGWELD/ESAB’s sole option,
of any components or parts of the product determined by CIGWELD/ESAB to be defective.
CIGWELD/ESAB MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL
OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: CIGWELD SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR
CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION.
The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD/ESAB with respect to any contract, or anything
done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any
goods covered by or furnished by CIGWELD/ESAB whether arising out of contract, negligence, strict tort, or under any warranty, or
otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee,
agent, or representative of CIGWELD/ESAB is authorized to change this warranty in any way or grant any other warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN
CIGWELD’S or ESAB’s SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY CIGWELD PRODUCT. PURCHASER’S
RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the
Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from
the date CIGWELD delivered the product to the authorized distributor.
Any claim under this warranty must be made within the warranty period which commences on the date of purchase of the product.
To make a claim under the warranty, take the product (with proof of purchase from a CIGWELD/ESAB Accredited Seller) to the store
where you purchased the product or contact CIGWELD/ESAB Customer Care 1300 654 674 for advice on your nearest Service Provider.
CIGWELD/ESAB reserves the right to request documented evidence of date of purchase. CIGWELD/ESAB or our Accredited Distributor
must be notified in writing of its claim within seven (7) days of becoming aware of the basis thereof, and at its own expense returning
the goods which are the subject of the claim to CIGWELD/ESAB or nominated Accredited Distributor/Accredited Service Provider.
This warranty is given.
CIGWELD Pty Ltd
CIGWELD An ESAB Brand
A.B.N. 56007226815
71 Gower Street, Preston Victoria, Australia, 3072
Phone: [phone] | Email: [email protected] | Website: www.cigweld.com.au | www.esabasia.com
This warranty is provided in addition to other rights and remedies you have under law: Our goods come with guarantees which cannot
be excluded under the Australian Consumer Law. You are entitled to replacement or refund for a major failure and to compensation
for other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of
acceptable quality and the failure does not amount to a major failure.
Please note that the information detailed in this statement supersedes any prior published data produced by CIGWELD or ESAB.

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Arcmaster Welding Helmet
WARRANTY SCHEDULE- ARCMASTER AUTO-DARKENING WELDING
HELMET
CIGWELD reserves the right to request documented evidence of date of purchase.
CIGWELD SAFETY EQUIPMENT WARRANTY PERIOD
Arcmaster 649 Auto-Darkening Welding Helmet ......................................................... ..............2 years
ACCESSORIES
Cover Lenses............................................................................................................... ............1 month
Sweat Band ................................................................................................................. .............1 month
CIGWELD Limited Warranty does not apply to;
• Obsolete goods sold at auction, second-hand goods and prototype goods.
• Consumable Parts for MIG, TIG, Plasma welding, Plasma cutting and Oxy fuel torches, O-rings, fuses, filters or other parts that
fail due to normal wear.
Note:
• No employee, agent, or representative of CIGWELD or ESAB is authorized to change this warranty in any way or grant any other
warranty, and CIGWELD/ESAB shall not be bound by any such attempt. Correction of nonconformities, in the manner and time
provided herein, constitutes fulfilment of CIGWELD/ESAB’s obligations to purchaser with respect to the product.
• This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in CIGWELD/
ESAB’s sole judgment, impaired the safety or performance of any CIGWELD/ESAB product and if the unit is altered or serviced
by an unauthorised CIGWELD/ESAB Service Provider. Purchaser’s rights under this warranty are void if the product is sold to
purchaser by unauthorized persons.
Please note that the information detailed in this statement supersedes any prior published data produced by CIGWELD.
!
!
WARNING
For the purpose of safety and performance and to protect your CIGWELD Equipment Warranty always use genuine CIGWELD
replacement parts and accessories.

10 0-5296
Arcmaster Welding Helmet
SECTION 2: Introduction
2.01 How to Use This Manual
This Operating Manual usually applies to just the underlined
specification or part numbers listed. If none are underlined, they
are all covered by this manual.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the word WARNING, CAUTION and NOTE
may appear. Pay particular attention to the information provided
under these headings. These special annotations are easily
recognised as follows:
!!
WARNING
Gives information regarding possible personal injury.
Warnings will be enclosed in a box such as this.
!
!
CAUTION
Refers to possible equipment damage. Cautions will
be shown in bold type.
NOTE
Offers helpful information concerning certain operating
procedures. Notes will be shown in italics.
2.02 Equipment Identification
The product identification number is printed on the outer shipping
carton. Record this number for future reference.
2.03 Receipt of Equipment
When you receive the equipment, check it against the invoice to
make sure it is complete and inspect the equipment for possible
damage due to shipping. If there is any damage, notify the carrier
immediately to file a claim. Furnish complete information concerning
damage claims or shipping errors to:
CIGWELD, Customer Care Department, 71 Gower St, Preston,
Victoria, Australia, 3072, [email protected].
Include all equipment identification numbers as described above
along with a full description of the parts in error.
Additional copies of this manual may be downloaded by visiting
www.cigweld.com.au/manuals/ or by contacting CIGWELD,
Customer Care Department, at the address given above. Include the
Operating Manual number and equipment identification numbers.
SECTION 3: General Information
3.01 Arcmaster Auto-Darkening Welding Helmet
The CIGWELD Arcmaster 649 Auto-Darkening Welding Helmet is a sophisticated and modern helmet specifically engineered for welding
comfort, versatility, performance and fume deflection. The Arcmaster 649 Auto Darkening Filter is fitted with an Ultra View True Colour
Lens with Blue Light Filter to assist in reducing the operator’s visual fatigue if concentrating on an arc all day. Four sensors detect the
arc and darken the lens in less than 0.2ms. Even at very low amperages, the helmet remains dark which makes it ideal for TIG work as
well as more powerful stick and MIG jobs, and a simple switch allows you to choose between welding and grinding modes. To ensure
your complete satisfaction with your new Arcmaster 649 Auto-Darkening Welding Helmet and to realise a safer work environment, we
ask that you read the following Operating Manual thoroughly before use.
3.02 User Responsibility
This product will perform as per the information contained herein when installed, operated, maintained and repaired in accordance
with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are
broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become
necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by CIGWELD. Advice in this
regard can be obtained by contacting an accredited CIGWELD Distributor.
This product or any of its parts should not be altered from standard specification without prior written approval of CIGWELD. The user
of this product shall have the sole responsibility for any malfunction which results from improper use or unauthorised modification from
standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved
by CIGWELD.