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Answers on choosing, fitting and looking after the spare parts for a belt-worn, powered-air welding helmet system with flow control.
Most parts of a powered-air system are consumable or wear items. The filters clog, the battery loses capacity, and the face seal, head cover and headband can stretch, split or harden. Lenses become pitted by spatter, the breathing hose can crack or leak, and belt straps and clips can fray.A sensible habit is to look over every part before each shift and replace anything damaged rather than waiting for a failure. HSE guidance lists changing filters, cleaning, checking straps and checking battery charge and flow rate as key maintenance tasks for powered respirators.
There is no single interval. Filters have limited capacity and can clog, making the airflow drop, so they should be changed when necessary and in line with the maker's instructions. Heavy fume, dusty conditions and long shifts all shorten filter life. A low-flow warning, shorter battery run time or reduced airflow are common signs that a filter is loaded.A particle filter does not remove welding gases. HSE notes that particulate filters will not protect against the gases in welding fume, so if gases are a concern, the maker's instructions and your risk assessment should decide the filter type.
Use only the battery and charger the maker specifies, and check the battery for damage before each use. Stop using a damaged pack. HSE guidance asks that battery-powered equipment is fully charged before use, and that battery charge is checked as part of routine maintenance.A battery that gives noticeably shorter run time, or will no longer hold a full charge, is nearing the end of its life. Nickel-metal-hydride packs generally keep best when kept clean, stored as the maker advises and not left deeply discharged. Charging limits and storage temperatures vary, so follow the manual.
Leave the work area immediately. HSE guidance says never to keep working if the fan stops or the flow rate falls. A loose-fitting helmet may still give some protection if the fan fails, but you should move to a safe area and find the cause.Common causes are a clogged filter, a flat or worn battery, a kinked or damaged breathing hose, or a poorly seated filter. Do not go back to welding until the fault is fixed and the flow has been checked as the manual describes.