schweisskraft VarioProtect XXL-W TC AIR TH3 User manual

VarioProtect XXL-W TC AIR TH3
Operating Instructions
VarioProtect XXL-W TC AIR TH3
VARIO PROTECT
Automatic welding helmet
with air filter system

2 VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN
Imprint
Product identification
Automatic welding helmet Item number
VarioProtect XXL-W TC AIR TH3 165 4055
Manufacturer
Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Fax: [phone] - 55
Email: [email protected]
Internet: www.schweisskraft.de
Information on the operating instructions
Original operating instructions
according to DIN EN ISO 20607:2019
Edition: 18.10.2022
Version: 1.06
Language: english
Author: MS/SN
Copyright information
Copyright © 2022 Stuermer Maschinen GmbH,
Hallstadt, Germany.
Technical changes and errors reserved.
Contents
1 Introduction ............................................. 3
1.1 Copyright ............................................................ 3
1.2 Customer service................................................ 3
1.3 Limitation of liability............................................. 3
2 Safety ....................................................... 3
2.1 Explanation of symbols....................................... 3
2.2 Safety regulations............................................... 4
2.3 Safety data sheets.............................................. 5
3 Intended use............................................ 5
3.1 Reasonably foreseeable Misapplication ............ 5
3.2 Residual risks ..................................................... 5
4 Technical Data......................................... 6
5 Type plate ................................................ 6
6 Description .............................................. 7
6.1 Identification and explanation ............................. 8
6.2 Accessories ........................................................ 8
7 Transport, packaging, storage............... 8
7.1 Delivery and transport......................................... 8
7.2 Packaging........................................................... 8
7.3 Storage ............................................................... 8
8 Product properties and setting options...8
8.1 Selection of the delay time.................................. 9
8.2 Adjustment of the sensitivity ............................... 9
8.3 Setting of the operating mode............................. 9
8.4 Setting of the the protection level ....................... 9
8.5 Memory............................................................... 9
8.6 Adjustment options of the headbands .............. 10
8.7 Setting the air flow level.................................... 10
9 Unpacking, Assembling ....................... 10
10 Warning notices .................................. 11
11 Procedure for recognizing a failure
of the darkening filter ......................... 11
12 Before putting into commissioning... 11
12.1 Inserting the battery....................................... 11
12.2 Acoustic warning signal of the charge level... 11
12.3 Charging the battery ...................................... 12
12.4 Putting on the respirator system................... 13
12.5 Connecting the air line ................................... 13
13 Utilization ............................................. 14
13.1 Adjustment of the air flow .............................. 14
13.2 Air flow test .................................................... 14
13.3 Air flow alarm test .......................................... 15
13.4 Adjustment of the helmet............................... 15
13.5 LCD-Display................................................... 15
13.6 Setting the air flow level................................. 16
14 Common problems and solutions ..... 16
15 Fault table for the respirator system. 17
16 Color table ........................................... 18
17 Meaning of the marking...................... 18
18 Care, maintenance and repair............ 19
18.1 Care by cleaning............................................ 19
18.2 Instructions for cleaning and disinfection...... 19
18.3 Replacement of the lenses ............................ 19
18.4 Respirator system.......................................... 20
18.5 Replacing the air filter.................................... 20
18.6 Inserting the battery....................................... 21
18.7 Charging the battery ...................................... 21
18.8 Maintenance/Repair....................................... 22
19 Disposal, recycling of old devices .... 22
19.1 Decommission ............................................... 22
19.2 Disposal via municipal collection points......... 22
19.3 Disposal of the new device packaging.......... 22
20 Spare parts .......................................... 23
20.1 Spare parts order........................................... 23
20.2 Spare part drawings....................................... 24
21 EC Declaration of Conformity ............ 26
22 Notes .................................................... 27

Introduction
VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN 3
1 Introduction
With the purchase of the welding helmet from SCH-
WEISSKRAFT you have made a good choice.
Read the operating instructions carefully before
commissioning.
This provides information on the correct commissioning,
the intended use as well as the safe and efficient opera-
tion and maintenance of the welding helmet.
The operating instructions are part of the welding helmet.
It must always be kept at the place of use of the welding
helmet. In addition, the local accident prevention regula-
tions and general safety regulations for the area of appli-
cation of the welding helmet apply.
Illustrations in these operating instructions are for basic
understanding and may differ from the actual version.
1.1 Copyright
The contents of these instructions are protected by copy-
right and are the sole property of Stürmer Maschinen
GmbH. Their use is permitted within the scope of the use
of the automatic welding helmet. Any other use is not
permitted without the written consent of the manufac-
turer.
Passing on and copying of this document, utilization and
communication of its contents are prohibited unless ex-
pressly permitted. We register trademark, patent and de-
sign rights for the protection of our products, insofar as
this is possible in individual cases. We emphatically op-
pose any infringement of our intellectual property.
1.2 Customer service
If you have any questions about your Automatic welding
helmet or for technical information, please contact your
specialist dealer. They will be happy to provide you with
expert advice and information.
Germany:
Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Repair-Service:
Fax: [phone]
Email: [e-mail]
Spare parts order :
Fax: [phone]
Email: [e-mail]
We are always interested in information and experiences
that result from the application and that can be valuable
for improving our products.
1.3 Limitation of liability
All information and instructions in the operating instruc-
tions have been compiled taking into account the appli-
cable standards and regulations, the state of the art and
our many years of knowledge and experience.
The manufacturer assumes no liability for damage in the
following cases:
- Non-observance of the operating instructions,
- Improper use,
- Use of untrained personnel,
- Unauthorized modifications,
- Technical changes,
- Use of unauthorized spare parts.
The actual scope of delivery may deviate from the expla-
nations and illustrations described here in the case of
special designs, when using additional order options or
due to the latest technical changes.
The obligations agreed in the delivery contract, the gen-
eral terms and conditions as well as the delivery condi-
tions of the manufacturer and the legal regulations valid
at the time of the conclusion of the contract apply.
2 Safety
This section provides an overview of all important safety
packages for the protection of people and for safe and
trouble-free operation. Further task-related safety in-
structions are contained in the individual chapters.
2.1 Explanation of symbols
Safety instructions
Safety instructions are identified by symbols in these op-
erating instructions. The safety instructions are intro-
duced by signal words that express the extent of the haz-
ard.

4 VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN
Safety
Tips and recommendations
In order to reduce the risk of personal injury and property
damage and to avoid dangerous situations, the safety in-
structions listed in these operating instructions must be
observed.
2.2 Safety regulations
• This welding helmet is not suitable for use in laser weld-
ing.
• Check the Automatic welding helmet for externally visi-
ble damage and defects before commissioning.
• Eliminate defects and damage immediately.
• Do not use the Automatic welding helmet in damp, wet
surroundings, rain, etc..
• Make sure that no water or other liquids can enter the
fan housing, the filter or the battery compartment.
• Never use the welding helmet in environments
- which contain unknown substances and / or have
an oxygen content below 17%.
- with the risk of explosion or fire
- with poor ventilation
- with strong wind
• If the respirator system stops working, the welding work
must be stopped immediately and the work area must
be left.
• Never use the welding helmet without a filter.
• Use only original spare parts and accessories.
• Never place this welding helmet or the filter on a hot
surface.
• Protect the filter from contamination.
• Never open the welding filter.
• Before using the welding helmet, make sure that the
operating mode is set correctly. - “Welding” or “Grind-
ing”.
• This welding helmet will not protect you from explosive
devices or corrosive liquids.
• Do not make any changes, either to the welding filter or
the welding helmet, unless this is expressly stated in
these operating instructions. Use only original spare
parts. Unauthorized spare parts can involve risks and
will invalidate the guarantee.
• If the viewing window does not darken immediately af-
ter the welding arc is ignited, welding must be stopped
immediately. Contact your supervisor or your dealer im-
mediately.
• Do not immerse the viewing window in water.
• Do not use solvents on the viewing window or helmet.
• Use the welding helmet only at temperatures between -
5 ° C and +55 ° C.
DANGER!
This combination of symbol and signal word indicates
an imminently dangerous situation that will result in
death or serious injuries if it is not avoided.
WARNiNG!
This combination of symbol and signal word indicates
a possibly dangerous situation that will result in death
or serious injuries if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates
a possibly dangerous situation which can lead to
minor or light injuries if it is not avoided.
ATTENTION!
This combination of symbol and signal word indicates
a potentially dangerous situation that can lead to
property and environmental damage if it is not
avoided.
NOTE!
This combination of symbol and signal word indicates
a potentially dangerous situation that can lead to
property and environmental damage if it is not
avoided.
Tips and recommendations
This symbol highlights useful tips and recommenda-
tions as well as information for efficient and trouble-
free operation.
ATTENTION!
Serious injuries can occur if the user ignores the warn-
ings and / or refuses to follow the instructions in the
operating manual!
ATTENTION!
Before using the welding helmet, the protective films
on both sides of the protective lenses must be
removed.

Intended use
VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN 5
• Store the helmet at temperatures between -10 ° C and
+55 ° C.
• If the welding helmet has been stored at temperatures
below 0 ° C, you must wait for a warm-up time so that
the battery can reach its full capacity.
• Protect the viewing window from liquids and dirt.
• Clean the viewing window regularly and do not use
strong detergents. Keep the sensors and solar panel
clean by using a clean lint-free cloth.
• Replace the sensors if they are damaged.
• Replace the inner lens and the outer lens regularly if
they are scratched or damaged.
2.3 Safety data sheets
Safety data sheets on hazardous materials can be ob-
tained from your specialist dealer or by calling +49
(0)951/96555-0.Specialist dealers can find safety data
sheets in the download area of the partner portal.
3 Intended use
The Automatic welding helmet VarioProtect XXL-W TC
AIR TH3 is exclusively designed to protect the eyes of
welders from harmful radiation in the visible, ultraviolet
(UV) and infrared (IR) range and is intended for use in
gas shielded arc welding (MAG/MIG), tungsten inert gas
welding (TIG), stick electrode welding (MMA) and
plasma cutting.
The respiratory protection system protects against parti-
cle contamination in accordance with the requirements
of EN 12941, equipment class TH3P. To ensure nominal
protection, no leakage may occur while wearing the wel-
ding helmet.
Intended use also includes compliance with all the infor-
mation in these instructions.
3.1 Reasonably foreseeable Misapplication
Any use beyond the intended use or any other use is
considered misuse.
Possible misapplications may include:
- Use in areas with hazardous substances, risk of ex-
plosion or fire.
- Failure to observe signs of wear and damage.
- Bypassing or modifying the protective devices.
- Non-observance of the maintenance instructions.
- Installation of spare parts and use of accessories
and equipment not approved by the manufacturer.
- Deliberate or careless handling of the Automatic
welding helmet during operation.
Misuse of the Automatic welding helmet can lead to
dangerous situations.
Stürmer Maschinen GmbH accepts no liability for design
and technical modifications to the Automatic welding
helmet.
Claims of any kind for damage due to improper use are
excluded.
3.2 Residual risks
Even if all safety regulations are observed and the ma-
chine is used in accordance with the regulations, there
are still residual risks, which are listed below.
- Eye damage when using defective or unsuitable filter
cartridge.
- Never use the welding helmet with the air supply sy-
stem switched off.

6 VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN
Technical Data
4 Technical Data Classification TH3 P R (SL):
TH3 defines the protection level
P R defines the filter type (P=particle filter, R= reusable
particle filter).
SL: Filter was tested against liquid and solid particles.
Duration of use of the viewing window
The period of use of the viewing window is approx. 2
years with normal to intensive use.
It is recommended to check the viewing window regularly
for scratches or impairment of a clear view and to re-
place it if necessary.
5 Type plate
Fig. 1: Type plate
Technical Data VarioProtect XXL-W TC
AIR TH3
Dimensions of the cassette 114 x 133 x 9,5 mm
Viewing window 100 mm x 83,4 mm
UV/IR-protection DIN 13
Bright level Protection level 4
Dark protection levels
(colour selection)
5 - 9 and 9 -13
Number of sensors 4
ON/OFF Fully automatic
Solar cells yes
Class 1/1/1/1
Functions "WELD" (welding) /
"GRIND" (grinding)
Changeover response
time from light to dark
0,08 ms
Lightening time DELAY
from dark to light
100 ms to 900 ms
continuous
Application temperature -5 °C to +55 °C
Replaceable battery yes, rechargeable, 4400
mAh
Battery charging time 3,5 hours
Storage temperature -10 °C to +55 °C
Weight air filter unit (unit +
battery + holder + hose)
1621 g
Weight welding helmet 842 g
Total weight 2463 g
Welding mask material Nylon
Hose length
respiratory protection
1000 / 1200 mm
Air flow respiratory pro-
tection level 1 / 2 / 3 170 / 200 / 230 l/min.
Filter battery runtime
step 1 / 2 / 3 8 / 6 / 4 hours
Sound pressure level < 73 dB(A)
Filter efficiency 0,3 µm
Filter type TH3 P R SL
DANGER!
Sight glasses made of mineral glass may only be used
together with suitable backing washers.

Description
VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN 7
6 Description
Fig. 2: Device description VarioProtect XXL-W TC AIR TH3
1 Welding helmet
2 Respiratory protection line
3 Respirator system
4 Adjustment knob for the rear headband
5 Side adjustment knob for vertical helmet position
6 Viewing window
7 Display
8 MEMORY - memory
9 Adjustment of the DELAY-time
10 Adjustment of the SENSITIVITY
11 Adjustment of the protection levels (SHADE)
12 Operating mode switch (WELD / GRIND)
13 Hose connection
Fig. 3: Display
Battery indicator
If the battery capacity is low, the battery must be
changed. Otherwise, the lighten and darken times will
slow down.
3
4
6
7
8
2
1
5
9
1
1
1
1
Button
Battery status display
Operating mode display
WELDING
Operating mode display
GRIND
Display color selection
protection levels 5-9
Display color selection
protection levels 9 - 13
Display sensitivity level
SENSITIVITY
1 = low, 5 = high
Display DELAY-time
1 = short (0,1s), 5 = long (0,9s)
Protection level display
SHADE
Selection of the memory number

8 VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN
Transport, packaging, storage
6.1 Identification and explanation
Inner lens and outer lens : SWM 1 B CE
SWM: Stürmer Werkzeuge Maschinen
1: Optical class
B: Level of mechanical strength: Protection against high
speed particles B (120 m/s)
CE: CE marking
Welding helmet: SWM EN 175 B CE
SWM: Stürmer Werkzeuge Maschinen
EN: Standard 175
B: Level of mechanical strength: Protection against high
speed particles B (120 m/s)
CE: CE marking
6.2 Accessories
7 Transport, packaging, storage
7.1 Delivery and transport
Delivery
Check the welding helmet for visible transport damage
after delivery. If the welding helmet shows signs of dam-
age, this must be reported immediately to the transport
company or the dealer.
7.2 Packaging
All packaging materials and packaging aids used in the
welding helmet are recyclable and must always be recy-
cled.
Cardboard packaging components have to be shredded
and brought to the waste paper collection.
The foils are made of polyethylene (PE) and the uphol-
stery parts are made of polystyrene (PS). These materi-
als are to be handed in to a recycling center or to the re-
sponsible waste disposal company.
7.3 Storage
The welding helmet must be thoroughly cleaned and
stored in a dry, clean environment at temperatures be-
tween -10 ° C and +55 ° C and a relative humidity of be-
low 90%.
If the welding helmet is not used for a longer period of
time, the battery must be fully charged, removed from
the filter system and stored separately.
8 Product properties and setting op-
tions
The shape of the helmet relieves the head and neck of
the welder, so the user feels more comfortable while
working.
As soon as an arc is struck, the photo sensors on the
welding filter react and darken the view in 0.08 millisec-
onds.
Designation Item
number
Quanti-
ties /
price unit
Con
tent
Outer lens 1662200 Packaging
Unit
1
Inner lens 1662201 Packaging
Unit
1
Headband complete
including air line
1662255 Piece 1
Front sweatband 1662203 Piece 1
Filter cassette 1662204 Piece 1
Housing welding
helmet
1662256 Piece 1
Filter coverage 1662250 Piece 1
TH3 -Filter 1662251 Piece 1
Prefilter 1662208 Piece 1
Spark barrier 1662209 Piece 1
Air filter system 1662252 Piece 1
Li-ION-battery 1662211 Piece 1
Air hose 1662253 Piece 1
Strap harness 1662213 Piece 1
Charger 1662214 Piece 1
Air flow tester 1662215 Piece 1
Holding frame of the
filter cassette
1662216 Piece 1
ATTENTION!
The buttons on the left side of the control panel must
be pressed twice to be active.

Product properties and setting options
VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN 9
8.1 Selection of the delay time
When welding is interrupted, the viewing window auto-
matically changes from dark to light, but with a preset de-
lay so that the glaring light from the afterglow on the
workpiece is dampened every time. The delay or re-
sponse time can be set with the DELAY button on the in-
side of the helmet between 100 ms and 900 ms as re-
quired.
To do this, press the button repeatedly until the desired
value appears in the display.
Fig. 4: Setting of the delay time
8.2 Adjustment of the sensitivity
Switching the filter to darkening can be set with the
“SENSITIVITY” button on the inside of the helmet.
To do this, press the button repeatedly until the desired
value appears in the display.
Before welding, set the sensitivity to the highest position
and adjust accordingly when welding.
Fig. 5: Adjustment of the sensitivity
8.3 Setting of the operating mode
With the operating mode switch you can choose be-
tween “WELD” (welding) with protection levels 5 - 9, 9 -
13 and “GRIND” (grinding). To do this, press the button
repeatedly until the desired setting appears in the dis-
play.
Fig. 6: Operating mode and protection level button
When grinding, the helmet protects against impacting
particles. The darkening function is switched off.
8.4 Setting of the the protection level
The protection levels (from 5 to 9 or from 9 to 13) are se-
lected with the protection level button SHADE on the in-
side of the helmet (Fig. 6).
To do this, press the button repeatedly until the desired
value appears in the display.
The welding filters completely protect the welder's eyes
and face from UV and IR radiation during welding work.
The UV / IR protection is always up to level 13. This
means that the user feels safe while welding.
Set the protection level before welding using the color ta-
ble (Fig. 23) according to the welding process used and
the welding current. If the darkening is too strong or too
little, adjust the value slightly with the button until the
welding point can be seen.
8.5 Memory
The MEMORY buttons can be used to save three set-
tings.
Fig. 7: Memory buttons
The last setting is automatically saved when the helmet
is used (after approx. 5 minutes).
The last setting is automatically offered the next time the
helmet is used.
To save a special setting, press a MEMORY button and
hold it down until the MEMORY display stops flashing.
To call up the saved setting, press the corresponding
MEMORY button.
ATTENTION!
Before starting welding, the operating mode switch
must be set to a protection level for welding again.
ATTENTION!
If the welding helmet is used for a long time with the
wrong protection level, the eyes can be injured.
NOTE!
The memory function is only available in the WELD-
ING operating mode.

10 VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN
Unpacking, Assembling
8.6 Adjustment options of the headbands
Fig. 8: Adjustment of the headbands
1. Upper headband W (Fig. 8) - Adjustment option wider
or narrower in the direction of the arrow to adjust the
helmet to a suitable position.
2. Lateral straps Z - Adjustment option in the direction of
the arrow on both sides by 3 positions, symmetrically
wider or narrower, in order to adjust the distance be-
tween the user's eyes and the filter lens. To adjust,
loosen the knobs on both outer sides of the helmet,
bring the helmet symmetrically to the appropriate posi-
tion and tighten the knobs again.
3. Rear headband Y - Adjustment option with rotary knob
wider or narrower to adjust the fit of the helmet looser
or tighter.
4. Angle of inclination X - setting options to adjust the
height of the user's eyes to the filter lens and the angle
of inclination of the helmet to the user's face. To ad-
just, loosen the knobs on the outside of the helmet,
move the helmet to the appropriate position and
tighten the knobs again.
The adjustment options of the headband result in maxi-
mum wearing comfort.
8.7 Setting the air flow level
The respirator system offers three settings for the air flow
to the helmet. The appropriate level can be set as re-
quired and should be tested by the user before starting
the welding work.
To switch off, hold down the OFF button for more than 3
seconds until the fan switches off.
9 Unpacking, Assembling
On delivery, check for completeness, intactness and cor-
rect assembly (Fig. 9).
Fig. 9: Scope of delivery
1 Welding helmet with air connection
2 Respirator system (suction device, filter + hip belt)
3 Lithium-ion battery
4 Extraction line with fire protection cloth and connec-
tion pieces
5 Shoulder strap
6 Air flow meter
7 Lithium-ion battery charger
8 Bag
If one of the parts shown is missing, the dealer must be
informed immediately.
W
Z
X
Y
But-
ton
Symbol
Press the button once to switch
on the device
Press button twice:
Air flow level 1 (approx. 170 L /
min.)
Press button three times:
Air flow level 2 (approx. 200 L /
min.)
Press button four times:
Air flow level 3 (approx. 230 L /
min.)

Warning notices
VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN 11
10 Warning notices
Eye protection devices against particles at high speed
represent a hazard for the wearer through the transmis-
sion of shocks when they are worn over conventional
corrective glasses.
If protection against high velocity particles at extreme
temperatures is required, the eye protection device cho-
sen should be marked with the letter T immediately after
the letter indicating the impact intensity. e.g. BT. Other-
wise the eye protection device may only be used at room
temperature.
11 Procedure for recognizing a failure
of the darkening filter
Before use, check the functionality of the dark switching
of the darkening filter by holding it up to a bright light
source.
12 Before putting into commissioning
• Before using for the first time, remove the protective
film from the inner lens and the outer lens (if available).
• Make sure the viewing window is clean and that no dirt
is covering the four sensors on the front of the filter cas-
sette. Make sure that the inner lens and the outer lens
are firmly seated in the frame.
• Check the respirator system for damage and make
sure it is working properly.
Before using the respirator system, check the airflow to
make sure it is providing a sufficient volume of air.
• Always wear the complete respirator system and do not
remove the head plate or never switch the air filter unit
off outside the contamination area.
Otherwise there is a risk that a high concentration of
CO2 will develop and the oxygen content in the upper
part of the head will drop, and thus little or no protection
will be given.
• If you are unclear about the pollutant concentration or
about the performance of the equipment, always ask
the occupational safety agent.
• Examine all parts for signs of wear and damage before
putting them into operation. Scratched, torn or holey
parts should be replaced immediately before the hel-
met is used again in order to avoid serious injuries.
• Make sure that the helmet is firmly in place before each
use.
• Select the shade number you need for the application.
To do this, turn the adjusting knob for the protection
level to the appropriate value. Make sure the setting is
correct by referring to the color table (Fig. 23).
• Adjust the headbands so that the welding helmet sits as
low as possible on the head and close to the face.
When using the welding helmet at a lower location, the
angle must be adjusted.
12.1 Inserting the battery
Fig. 10: Inserting of the battery
Step 1: Slide the battery into the slot on the back of the
filter unit until it clicks into place. Note the desig-
nation of the poles (Fig. 10, 1).
Step 2: Check that the battery is locked in place.
12.2 Acoustic warning signal of the
charge level
The device vibrates when the battery is low.
1
2

12 VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN
Before putting into commissioning
12.3 Charging the battery
After delivery the battery is partially charged.
It must be loaded to 100% (4 bars in the display) before
starting operation.
Fig. 11: Inserting the battery
The battery can either be inserted in the filter unit or
charged separately.
Fig. 12: Battery charger
The battery charger charges the battery automatically.
As soon as the battery is fully charged, the charger
switches to trickle charging, viz. the charge level is kept
at 100%.
Charging time: 3 to 4 hours.
Charge the battery every 15 days !
Before using the new battery for the first time or if it is
stored for longer than 3 months, it must first be fully
charged and then discharged twice and then charged
again in order to maintain its full capacity.
Step 1:Connect the battery to the charger. The contact is
on the top of the battery.
Step 2: Connect the charger to the mains. The charging
status is indicated by the red LED on the charger.
As soon as the battery is fully charged, the char-
ger switches to trickle charging. The LED display
changes to green.
Step 3: Disconnect the charger from the mains (do not
leave the charger unnecessarily connected to the
mains) and disconnect the battery.
ATTENTION!
The battery must be charged to 100% before start-
ing operation.
1
2
ATTENTION!
The battery charger may only be used to charge this
battery.
Never charge the battery in an explosive environ-
ment!
Only use the charger in closed rooms!
NOTE!
The battery discharges when it is stored for a long
period of time.
Always charge the battery after it has been stored for
more than 15 days.

Before putting into commissioning
VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN 13
12.4 Putting on the respirator system
Fig. 13: Putting on the respirator system
Step 1: Remove the belt buckle.
Step 2: Pull the fastening strap out of the 2 belt loops on
the belt.
Step 3: Guide the fastening strap through the 2 belt
loops of the respirator system.
Step 4: Position the Velcro between the 2 loops.
Step 5: Turn the filter system over and attach the Velcro
to the belt.
Step 6: Put the fastening strap back through the 2 belt
loops.
Step 7: Fasten the belt buckle again.
Step 8: Attach the strap to the 4 plastic rings on the
strap.
Step 9:Check that the belt is securely fastened.
12.5 Connecting the air line
Fig. 14: Connecting the air line
Step 1: Connect the air tube to the respirator system and
turn it clockwise to lock the connection.
Step 2: Connect the other end of the tube to the head
section of the helmet in the same way.
Step 3: Check that the air tubing is securely attached.
Replace the line if it leaks.
1
2
3
4
5
6
7
8
1
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14 VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN
Utilization
13 Utilization
13.1 Adjustment of the air flow
The air flow can be set in two ways using the switch on
the front of the inner hood (item 1, figure 15).
Fig. 15: Switch to adjust the flow
When the switch is in the right position, distribution takes
place in three zones (Fig. 16). The two outer zones each
receive 40% and the middle zone 20% of the air flow.
Fig. 16: Air distribution 40 %,20 % and 40%
With the switch in the left position, distribution is also car-
ried out in three zones (Fig.17). The two outer zones each
receive 10% and the middle zone 80% of the air flow.
Fig. 17: Air distribution 10%,80% and 10%
13.2 Air flow test
Fig. 18: Air flow test
ATTENTION!
Never use the welding helmet with the fan switched
off.
1
40 %
20%
40 %
10% 10%
80%
1
2
3
4

Utilization
VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN 15
Step 1: Connect the breathing tube to the turbo unit and
turn it clockwise to lock it in place.
Step 2: Insert the flow meter on top of the pipe.
Step 3: Press the ON button and hold the tube in a verti-
cal position at eye level.
Sept 4: The air flow is sufficient when the ball reaches
the minimum flow rate O. If the minimum flow
rate is not reached, replace the filter and / or bat-
tery and test the flow again.
13.3 Air flow alarm test
Fig. 19: Air flow alarm test
Step 1: Remove the tube from the helmet and press the
ON button.
Step 2: Cover the end of the pipe with your hand to
block the airflow and wait approx. 15 seconds.
The alarm must be triggered during this period. If
the alarm does not work, the respirator system
must be repaired or replaced.
13.4 Adjustment of the helmet
Fig. 20: Adjustment of the headband
Step 1: Pull the ring up to open the fabric seal and put
the helmet on.
Step 2: Adjust the headband so that the helmet fits exact
and tight . To do this, press and turn the knob left
to loosen the headgear and right to tighten.
13.5 LCD-Display
Fig. 21: LCD-Display
ATTENTION!
The air flow must be checked before using the hel-
met!
If the ball does not reach the minimum flow level, the
device must not be used!
1
2ATTENTION!
Check that the helmet seal is tight against the face.
Otherwise the protection factor is not guaranteed!
1
2
Pull
Push and turn
Untie Tighten

16 VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN
Common problems and solutions
1 Display of the current air flow (L/min.)
2 Display of the air flow level
3 Display of the filter status
4 Battery charge status display
5 Battery temperature display
In the event of a malfunction, the corresponding display
flashes.
13.6 Setting the air flow level
The respirator system switches off the air flow if the OFF
button is pressed for more than 3 seconds.
The respirator system interrupts the entire circuit and
switches to sleep mode if the air flow is switched off for
more than 30 minutes. The system can be activated by
pressing the ON button.
The respirator system must be used in the temperature
range of -5 ° C to + 55 ° C and a relative humidity of less
than 90%.
14 Common problems and solutions
Irregular darkening of the cassette
• The headband can be adjusted differently on both sides
of the helmet (asymmetrical distances between eyes
and viewing window). Readjust the headband and the
distance to the viewing window.
Automatic cassette does not darken or flickers
• Sensors dirty or solar panel covered.
--> Clean the surface of the sensors.
• Outer lens soiled or damaged.
--> Replace or clean the outer lens.
• Sensitivity is set too low or the delay time is set too
short.
--> Set to required value.
• Unsuitable protection level set .
--> Set a suitable protection level.
Automatic cassette darkens without arcing
• Sensitivity is set too high.
--> Set to required value.
The automatic cassette remains darkened after the
welding process has been completed
• The delay time is set too long.
--> Set to required value.
Too long response time
• Operating temperature too low.
--> Do not use below - 10 ° C.
Bad sight
• Outer lens and / or inner lens dirty.
--> Check, clean or replace outer lens and / or inner
lens.
• Insufficient ambient light.
--> Adjust ambient light.
• Shade number set incorrectly.
--> Use the color table for the correct setting.
Welding helmet is slipped
• Headbands not adjusted correctly.
--> Adjust the headbands correctly.
But-
ton
Symbol
Press the button once to switch
on the device
Press button twice:
Air flow level 1 (approx. 170 L /
min.)
Press button three times:
Air flow level 2 (approx. 200 L /
min.)
Press button four times:
Air flow level 3 (approx. 230 L /
min.)
WARNING!
The user must take off the welding helmet immedi-
ately if the above problems cannot be resolved. Con-
tact your dealer.
WARNING!
If the material comes into contact with the user's
skin, it could, in some circumstances, cause an aller-
gic reaction on the skin.

Fault table for the respirator system
VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN 17
15 Fault table for the respirator system
Audible warnings
Fig. 22: Table of acoustic warning signals
Each field of the grid stands for a period of 100 ms. The
beep is gray and the empty field is a silent phase. Sev-
eral continuous gray fields symbolize a continuous signal
tone.
Fault Cause Remedy
Error code E01 is displayed and
warning flashes.
1. Motor blocked.
2. Motor defective.
3. Blower failure due to external influ-
ences.
4. Defective circuit.
Check and remove physical errors
and reboot the system. Contact the
dealer if the LCD still shows E01 af-
ter this.
Error code E02 is displayed and
warning flashes.
1. Engine damaged.
2. The fan wheel stripes at the hous-
ing.
3. Excessive current flow in the cir-
cuit.
Check and remove physical errors
and reboot the system. Contact the
dealer if the LCD still shows E02 af-
ter this.
Battery symbol and
warning flashes. Acoustic
alarm signal sounds.
Low battery capacity. Charge the battery
Filter symbol and
warning flashes.Acoustic
alarm signal sounds.
1. Filter clogged.
2. Clogged line.
1. Clear the filter or line and clean it.
2. Replace filter if necessary.
Filter symbol flashes.
Acoustic alarm signal sounds.
High battery temperature. Interrupt work and take a break to
cool off the battery.
No air flow, no alarm 1. No power supply.
2. No battery contact.
1. Charge the battery.
2. Check and establish battery con-
tact.
Battery life too short 1. Battery not fully charged.
2. Filter clogged.
3. Battery damaged.
1. Charge the battery.
2. Clear the filter and clean it, replace
the filter if necessary.
3. Replace the battery.
The air supplied to the helmet smells
unusual 1. Broken filter.
2. Broken air pipe.
3. Helmet damaged.
Leave the work area immediately.
1. Replace filter.
2. Replace air line.
3. Replace helmet.
Insufficient air supply to the helmet 1. Air pipe broke off.
2. Broken air pipe.
3. Filter clogged.
1. Check and restore the connection
of the air pipe to the helmet and
the respirator system.
2. Replace air pipe.
3. Clear the filter and clean it, replace
the filter if necessary.

18 VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN
Color table
16 Color table
Fig. 23: Color table
17 Meaning of the marking
Each product is marked with a corresponding protection
level (5 to 9 and 9 to 13). Make sure that the correct pro-
tection level has been set before starting the welding
process. The classification for eye protection is accord-
ing to EN 379. Other markings on the product are in ac-
cordance with the relevant European standards.
Example filter (EN 379):
Fig. 24: Classification for eye protection
The welder head section and the outer lens are marked
with code letters, which indicate the protection class
against impact energy (flying parts):
F stands for low impact energy (45 m / s) and B stands
for medium impact energy (120 m / s). If the protective
equipment also meets the requirements for extreme tem-
peratures (-5 ° C to + 55 ° C), it is also marked with the
letter T.
welding procedure
metal arc welding
MIG welding for heavy metal
MIG welding for light alloy
Tungsten inert gas welding
Semi-automatic UP-welding
Plasma arc cutting
Plasma arc welding
Explanation
Light level
Weakest level of darkness
Strongest level of darkness
Code letter of the manufacturer
Optical class
Stray light class
Homogeneity class
Class of the angle properties (optional marking)
Certification mark or number of the standard
CAUTION!
The mechanical strength of the helmet can only be
as strong as its weakest part.

Care, maintenance and repair
VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN 19
18 Care, maintenance and repair
18.1 Care by cleaning
Clean the outside of the welding helmet with a damp
cloth.
Clean the solar cells and the light sensors of the filter
with a soft cloth or with a cloth dampened with a mild de-
tergent or alcohol.
18.2 Instructions for cleaning and
disinfection
The inner lens and the outer lens must be cleaned and
disinfected regularly.
18.3 Replacement of the lenses
Replacement of the outer lens if it is damaged
(cracked, scratched, dirty or holey)
1. Remove the filter holder from the housing by turning
the latches towards the middle.
2. Lift the filter holder to remove or replace the outer
lens.
Fig. 25: Replacement of the outer lens
Replacement of the inner lens if it is damaged
(cracked, scratched, dirty or holey)
1. Insert the fingernail into the recess below the inner
lens and lift up the inner lens.
2. Insert the new inner lens.
Replacement of the filter
1. Remove the filter cassette from the helmet shell (Fig.
25). Bend up the top of the filter housing to remove the
filter cassette from the frame.
2. Insert the new filter cassette into the frame (Fig. 26).
Make sure the filter cassette is properly seated in the
frame and put the filter casette back into the helmet
shell.
Fig. 26: Filter replacement
WARNING!
Danger from insufficient qualifica-
tion of persons!
Insufficiently qualified persons cannot assess the
risks for the user resulting from improper repair work
on the welding helmet and expose themselves and
others to the risk of serious injuries.
Have all maintenance work carried out by qualified
persons only.
NOTE!
After care, maintenance and repair work, check
whether all casing and protective devices have been
properly reassembled on the automatic welding hel-
met.
Damaged protective devices and device parts must
be repaired or replaced by customer service.
ATTENTION!
Never use aggressive solvents such as for example
acetone.

20 VarioProtect XXL-W TC AIR TH3 | Version 1.06 | EN
Care, maintenance and repair
18.4 Respirator system
Check the respirator systems regularly. If it is leaking or
damaged, it must be replaced!
The filter must be replaced if it is damaged or clogged
and does not provide enough air.
The breathing tube must be replaced if it is broken or
leaking.
The battery needs to be charged when the low battery
alarm sounds.
Wipe the outside of the respirator system components
with a soft cloth. Never use water!
The filter should be replaced together with the prefilter.
18.5 Replacing the air filter
Fig. 27: Filter replacement
The service life of the filter and prefilter is 12 months.
With intensive use, the condition of the filter should be
checked regularly at shorter intervals. If necessary, re-
place the filter parts more frequently than every 12
months.
Step 1:Remove the filter cover by pressing the latch on
the filter cover.
Step 2: Remove the cover.
Step 3: Take the filter out of the cover.
Step 4: Remove the prefilter.
Step 5: Clean or replace the spark arrester if necessary.
Step 6: Insert the new prefilter and filter into the cover.
Step 7: Put the cover with the new filter back into the
housing.
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