Sealey PWH599 User manual

Viewing area . . . . . . . .98 x 43mm (3.86 x 1.74).
Size of Cartridge . . . . .110x90x9mm (4.33x3.54x0.35)
Power supply . . . . . . . .Solar cells
Power On/Off. . . . . . . .Fully Automatic
UV/IR Protection . . . . .Up to shade Din.16 at all times
Adjustable shade . . . . .From 9 - 13
Clear state . . . . . . . . . .Shade DIN 3.
Response (light to dark) 1/20,000 sec
Response (dark to light) l Position slow = 0.6 - 0.8sec
. . . . . . . . . . . . . . . . . .lPosition fast = 0.25 - 0.35sec
Sensitivity . . . . . . . . . .Adjustable high/low
Helmet material . . . . . .Hi-impact Polyamide Nylon/Polyprop.
Total weight . . . . . . . . .435g
Operating temperature .-50C to 550C (230F to 1310F).
Storing temperature . . .-200C to 700C (-40F to 1580F).
PWH599 - 3 - 231003
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of this equipment. WARRANTY: Guarantee is 12 months from purchase date. proof of which will be
required for any claim. INFORMATION: Call us for a copy of our latest catalogue on 01284 757525 and leave your full name and address including your
postcode.
Thank you for purchasing a Sealey Power Product. Manufactured to a high
standard this product will, if used according to these instructions and properly
maintained, give you years of trouble free performance.
IMPORTANT:PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS,
WARNINGS AND CAUTIONS. USE THIS PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR
WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE OR PERSONAL INJURY, AND WILL
INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
AUTOMATIC WELDING HELMET
INSTRUCTIONS FOR MODEL NO: PWH599
1. SAFETY INSTRUCTIONS
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WARNING! THIS HELMET IS NOT SUITABLE FOR USE WITH LASER OR GAS-WELDING.
Ensure all workshop safety rules, regulations, and conditions are complied with when using welding equipment.
The helmet will not offer protection against mis-use of workshop tools, equipment, or accessories.
Maintain the helmet in good condition, and protect cartridge from liquid and dirt contact.
Regularly replace the protective lens and replace any damaged or worn parts. Use
genuine parts only. Non authorised parts may be dangerous and will invalidate the
warranty. NEVER open or tamper with the shade cartridge.
Select the shade level before use.
Ensure the front cover lens is securely in place before use.
Fit the helmet and adjust the head band so the helmet will sit as low and near to
your face as possible,
Use helmet only in temperatures ranging from -50C to 550C (230F to 1310F).
The eye protective plate in helmet is NOT unbreakable. Helmet will not protect
you against severe impact hazards (such as, but not limited to) fragmenting
abrasive discs/grinding wheels, stones and other grinding tools, explosive devices or
corrosive fluids. The helmet will only protect the eyes and face from radiation and sparks.
Remove ill fitting clothing, remove ties, watches, rings, and other loose jewellery. Maintain
correct balance and footing. Ensure the floor is not slippery and wear non slip shoes.
Keep children and unauthorised persons away from the working area.
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WARNING! DO NOT use the helmet if damaged or you suspect it may be faulty. (Contact Service Agent).
DO NOT use helmet unless you have been instructed in its use by a qualified person.
DO NOT get the helmet wet or use in damp or wet locations.
DO NOT leave work place with helmet in lowered position, as bright light source may darken cartridge unexpectedly.
DO NOT place the helmet on a hot surface.
Clean helmet (see section 5.9) and store the helmet in a safe, dry, childproof location.
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DANGER! If, at any time, the face plate in the cartridge FAILS to darken when exposed to a welding spark,
DO NOT USE. Remove cartridge and return to your dealer for checking. Continued use of the product
knowing that the auto darkening feature is NOT FUNCTIONING may DAMAGE YOUR EYES and CAUSE
BLINDNESS. Continued use of the helmet which is not functioning will invalidate the warranty and could
prohibit a successful claim on any insurance company.
3. SPECIFICATION
2. INTRODUCTION
High quality variable shade 9-13 lens manufactured and tested to BSEN379. Fully automatic, switches from light
to dark on striking arc. Fitted with solar power panel, no batteries required. Features sensitivity switch and delay
speed switch control for switching dark to light, preventing arc eye when welding at high power, whilst still providing
fast switching for tack welding. Deluxe contoured helmet design approved to BSEN175 gives full neck protection
and protects lens from scratching when helmet is laid down. Comfortable headband and non slip quick release
ratchet mechanism. Suitable for MIG and arc welding. (Not suitable for use with laser or gas-welding).
01284 757500
01284 703534
E-mail: [e-mail]
Sole UK Distributor
Sealey Group,
Bury St. Edmunds, Suffolk.
Web address: www.sealey.co.uk
7. SPARE PARTS
REF. PART NO. DESCRIPTION
(fig.4) 168/445505 Front cover lens 112x93mm
(fig.5a) 168/445510 Shade cartridge
168/445525 Shade knob
168/445530 Inside cover lens
168/445535 Helmet shell
(fig.6-X) 168/445540 Sweat band
(fig.6) 168/445545 Adjustable Head band
(fig.6-6) 168/445550 Block nut
(fig.6-2) 168/445555 Washer x 4
(fig.6-4) 168/445560 Limitation washer (adjustable)
(fig.6-3) 168/445565 Limitation washer LEFT
(fig.2) 168/445570 Screw
(fig.6-3) 168/445575 Limitation washer RIGHT
IRREGULAR DARKENING The headband may have been unevenly set on the two Readjust the distance of the shade
OR DIMMING. sides of the helmet (unequal distances from the eyes cartridge.
to the shade cartridge).
SHADE CARTRIDGE DOES The sensors are soiled or obstructed. Clean
NOT DARKEN OR FLICKERS. Front cover lens oiled or damaged. Clean or replace
Welding current too low.Adjust weld amps
POOR VISION Operative lenses and/or shade cartridge soiled. Check, clean or replace
Insufficient ambient light. Adjust light
Shade level incorrectly set. Refer to Shade Guide for setting
SLOW RESPONSE Operating temperature too low Do not use at temperatures
below -50C (230F) .
WELDING HELMET SLIPS Headband adjustments incorrect. Refer to section 4.
6. PROBLEM SOLVING
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DANGER! If, at any time, the face plate in the cartridge FAILS to darken when exposed to a welding spark, DO NOT USE.
Remove cartridge and return to your dealer for checking. Continued use of the product with auto darkening feature NOT
FUNCTIONING may DAMAGE YOUR EYES and CAUSE BLINDNESS. Use of malfunctioning product will invalidate the
warranty, and any right of claim on any insurance policy.
fig 6
Issue date 14/10/03
Issue No, 3

4. INSTRUCTIONS FOR USE
pWARNING! Before using the helmet for welding ensure you have
read and understood the safety instructions in Section 1.
4.0 The helmet comes ready assembled but before it can be used
it must be adjusted to fit the user properly and set up for
response time, sensitivity and shade level.
4.7 SELECTING DELAY TIME When welding ceases the viewing
window automatically changes from dark back to light but with
a pre-set delay to compensate for any bright afterglow on the
workpiece. The delay time/response can be set to fast (0.25secs to
0.35) or slow (0.5secs to 0.8) as you require using the microswitch
on the back of the shade cartridge. (See fig.3 )
4.8 SENSITIVITY The sensitivity can be set to high or low using
the microswitch on the back of the shade cartridge. The high setting is
the normal setting for everyday use. Where the operation of the mask is disturbed by excess light or another welding
machine close by, use the low setting. (See fig.3).
4.9 You are now ready to use the helmet. The shading may be adjusted during use by re-setting potentiometer control.
4.1 ADJUSTING THE FIT OF THE HELMET The overall
circumference of the headband can be made larger or
smaller by rotating the knob on the back of the headband.
(See adjustment Y in fig.1) This can be done whilst
wearing the helmet and allows just the right tension to be
set to keep the helmet firmly on the head without it being
too tight.
4.2 If the headband is riding too high or too low on your
head adjust the strap which passes over the top of your
head. To do this release the end of the band by pushing
the locking pip out of the hole in the band. Slide the two
portions of the band to a greater or lesser width as
required and push the locking pip through the nearest
hole (See adjustment W in fig.1)
4.3 Test the fit of the headband by lifting up and closing
down the helmet a few times whilst wearing it. If the headband
moves whilst tilting re-adjust it until it is stable.
4.4 ADJUSTING DISTANCE BETWEEN HELMET & FACE
To adjust the distance between the helmet and your face in the down position loosen the tilt knobs on
either side of the helmet and slide it nearer to or further from your face. (See adjustment Z in fig.1) It is
important that your eyes are each the same distance from the lens otherwise the darkening effect may
appear uneven. Re-tighten the tilt knobs when adjustment is complete.
4.5 ADJUSTING ANGLE OF THE MASK IN THE DOWN POSITION If the
lens is not properly aligned with the eyes in the down position the
mask angle can be further adjusted into one of three preset
positions using the tilt plate shown in fig.2. Behind each pivot
knob on the sides of the helmet there is a screw which passes
through the side of the mask and into one of the holes in the tilt
plate ( see A,B,C in fig.2 ). Partially undo each screw
anticlockwise so that it withdraws out of the tilt plate but remains
in the side of the mask. Rotate the headband assembly so that
one of the alternative positions is aligned with the end of the
screw. Turn the screws clockwise again so that they pass through
the holes thus fixing the position of the tilt plate.
4.6 SELECTING SHADE LEVEL Select the shade level you require
according to the welding process you will use by referring to the Shade
Guide below for settings. Turn the shade control knob on the side of the
helmet to the shade number required.
fig.2
fig 3
5. MAINTENANCE
fig.1
Declaration of Conformity We, the sole importer into the UK, declare that the product listed here is
in conformity with the following EEC standards and directives. The construction file for this product is held
by the Manufacturer and may be inspected on request by contacting Jack Sealey Ltd
For Jack Sealey Ltd. Sole importer into the UK of Sealey Power Products
Signed by Mark Sweetman 20th June 2003
Automatic Welding Helmet
Model PWH599
BS EN 175,1997 BS EN 169,2002
BS EN 379,1994
5.1 REPLACING FRONT COVER LENS. Place your
finger or thumb into the recess at the bottom edge of
the window and flex the window upwards until it
releases from one edge. (See fig.4-C). Remove the
protective film from the new window and pass one
edge under the side retaining lip shown at A in fig.4.
Flex the window upwards and tuck the other edge
under the opposite retaining lip as shown at B in fig.4.
5.2 CHANGING THE SHADE CARTRIDGE.
(See figs.5a & 5b) Pull off the shade control knob
leaving the shaft protruding through the helmet side.
Unfasten the nut on the shaft and leave the
potentiometer loose on its cable. The cartridge is
retained by a wire loop clip as shown in fig.5b. Release the front edge of the clip (fig.5a-D) from its
retaining lugs (fig.5a-E) and hinge it upwards and out of the way. Lift the shade cartridge out of its frame
complete with the shade control potentiometer on its lead.
5.3 FITTING NEW CARTRIDGE. Take the new shade cartridge and pass the potentiometer cable under the
wire loop before dropping the cartridge into its retaining frame inside the helmet. Hinge down the wire loop
clip and ensure that the front edge of the loop is properly retained under the retaining lugs as shown in fig.5b
5.4 Fasten the nut on the shaft protruding through the hole. Push the shade control knob onto the shaft.
5.5 CLEANING. Clean helmet by wiping with a soft cloth. Clean cartridge surfaces regularly. Do not use strong
cleaning solutions. Clean sensors and solar cells with
methylated spirit and a clean cloth and wipe dry with
a lint-free cloth. fig 5a
fig 5b
PWH599 - 3 - 231003
fig 4