Practical answers on face seals, hoses, belts, adaptors and visor parts for a compressed-air-fed welding helmet system.
What should I check before replacing an air hose adaptor or connector?
Check that it is specified for your helmet and air unit. Maker manuals for this type of air-fed equipment say to use only the hose and connections supplied or specified by the maker, because a different hose or fitting can change the airflow and the level of protection.
Compare the old adaptor with the new one for thread, connector style and the end it fits (helmet end or unit end). Look at the markings and the manual's parts list rather than relying on appearance. If the connector is cracked, worn or leaks, replace it before the next use. Our team can help you match it to your equipment.
What does a face seal do and when does it need replacing?
A face seal closes the gap between the helmet and your face, so that supplied air is directed over your breathing zone and fume has less chance of entering. HSE guidance lists maintaining and replacing valves and checking straps for damage as key maintenance tasks, and a worn or damaged seal should be treated in the same way.
Signs of wear include splits, hardening, stretching, curling edges and marks that will not wash off. Trade guidance suggests a seal may need changing about every couple of months with heavy daily use, and sooner in dirty work, but follow the maker's manual. Do not use a seal that has lost its shape.
Can I use any air hose with my helmet, and how do I protect it?
No. Use only the hose specified for your unit, because a different hose or fitting can change the airflow and the protection you get. Maker manuals for this type of unit also say to use the system only where the supply hose is unlikely to be damaged, and that the hose must not be exposed to sparks, even if a protection cover is fitted.
HSE guidance warns that trailing hoses can snag and be damaged, and says never to use a light-duty airline hose where vehicles or passers-by could crush it. Route the hose clear of hot work, sharp edges and traffic, and do not kink it. Inspect the hose and connections before each use and replace one that is cut, burnt, kinked or leaking.
What standard of air does the air-fed system need?
Air supplied to breathing apparatus must be clean and safe to breathe. HSE guidance says compressed air should meet the quality requirements of the breathing air standard, in addition to the pressure and airflow requirements of the equipment maker. Maker manuals for this type of unit also call for breathable air to that standard. Ordinary workshop compressed air is not the same thing.
HSE says air quality should be tested at least every three months, and more often if the quality cannot be assured, with records kept for five years. Check the airflow each time you use the equipment, and check the manual for the pressure range. Ask a competent person to check the compressor, filters and air quality.
What should I do if the airflow in the helmet feels low?
Stop welding, move away from the fume and check the system. HSE says to check the air flow every time the equipment is used, and to leave the area if you think the equipment is not working properly. A maker's manual for this type of unit also warns that under extreme workload the protection can be reduced.
Check for kinked or damaged hoses, loose connections, a clogged filter, and low supply pressure, as the manual describes. Do not carry on working until the cause is found and fixed.
Who should maintain the equipment and what records are needed?
HSE guidance on respiratory protective equipment says maintenance should follow the manufacturer's instructions and be carried out by a competent person. Thorough maintenance, examination and tests should be done at least once a month. If the equipment is used only occasionally, it should be examined and tested before use and in any event at intervals of no more than three months.
Records of examinations, tests and repairs must be kept for at least five years. Key tasks include cleaning, maintaining and replacing valves, checking straps and checking the flow. Air quality for compressed-air systems is tested separately, at least every three months. Your risk assessment and the maker's instructions set the final programme.