Replacement lenses, fittings and comfort parts for a passive welding helmet, and how to work out the right one.
Why must the filter and protection plates match my helmet, and how does the HSE see eye protection?
The HSE says welders need eye protection with filters to guard against arc eye, a painful injury to the front of the eye caused by welding radiation, which usually shows up a few hours after exposure. It says the filters should meet relevant British and European standards.
So never fit a filter or plate that is not made for your helmet and process. Makers say not to use any filter without its shade number and approval marking, and never to use a protection glass in place of the inner plastic safety plate. Do not use a cracked or loose part. Check the manual or ask your supplier if you are unsure which part is right.
Does a welding helmet protect me from welding fume?
No. A standard helmet protects the eyes, head and neck from arc radiation and spatter. It is designed for use where ventilation is sufficient, and a fresh-air helmet is recommended where ventilation is poor. The HSE says the best option for arc welders is a powered or supplied-air respirator that combines respiratory, eye and face protection.
Where fume controls such as local exhaust do not give adequate control, suitable respiratory equipment should be added, and it must work with the other protective equipment, such as the helmet. Ask your supplier or safety adviser, and follow your risk assessment.
When should I replace the cover plates in front of and behind the filter?
Check them before every use. Maker instructions say to replace protection plates straight away if they are scratched, damaged or built up with spatter so that vision is reduced, and to replace any cracked, pitted or scratched part.
Plastic plates scratch easily, so handle them carefully, and only fit the type of plate your helmet manual specifies. Sizes and fittings differ between helmets, so match the part to your helmet from the manual or the old part.
How do I clean the helmet and lenses without damaging them?
Blow loose dirt and dust off first, then wipe the helmet with a damp cloth wetted with mild soapy water, and dry it with a clean cloth. Maker instructions say not to use solvents or strong cleaning solutions. Plastic plates scratch easily, so handle them carefully.
Inspect the shell, headband, filter and plates for cracks, pitting or scratches each time you use the helmet, and replace anything damaged, because a damaged part reduces protection. Do not put the helmet down on a hot surface such as a hot weld, and keep it somewhere clean and dry. Follow the manual for your model.
How should I set up the headband so the helmet sits comfortably?
Adjust the height and girth of the headband for comfort. Set the band fairly low so the helmet stays firmly in place, with the sweatband a little above your eyebrows and ears, and tighten it with the adjusting wheel to suit your head.
Then set the helmet angle so that its lower edge is near your chest while welding, where protection is best, and adjust the pivot tightness so a raised helmet stays up but drops when you nod. If it strikes your chest as it falls, it is too loose or set too close to your face. Replace the headband if it is cracked or no longer holds its setting.
What do small fittings such as springs and adjuster sets do?
A filter retaining spring holds the filter and protection glass in the helmet's hatch frame, so a bent, weak or lost one can let parts shift. How it is released and refitted depends on the helmet, so follow the manual and make sure it is seated properly before use.
Adjuster sets are the parts, such as the adjustment plate and screws, that set the helmet angle and how tightly it pivots against the headband. They wear with use, so replace them when they are loose, cracked or no longer hold their setting. These parts are specific to a helmet family, so identify the right one from the manual's parts list or the old part rather than by appearance.